PDF

Operating Instructions
Diesel engine
12V 4000 M53R
16V 4000 M53R
MS150036/02E
Printed in Germany
2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
Table of Contents
1 Safety 5 Maintenance
1.1 Important provisions for all products 5 5.1 Maintenance task reference table [QL1] 99
1.2 Personnel and organizational requirements 6
1.3 Transport 7 6 Troubleshooting
1.4 Safety regulations for maintenance and
repair work 8 6.1 Troubleshooting 101
1.5 Fire prevention and environmental 6.2 Fuel treatment system Troubleshooting 104
protection, fluids and lubricants, auxiliary 6.3 Engine governor ADEC (ECU 7) fault
materials 11 messages for Series 4000 engines, marine
1.6 Standards for safety notices in the text 13 application 105
6.4 ADEC engine governor Fault codes 106
2 General Information
7 Task Description
2.1 Engine side and cylinder designations 14
2.2 Product description 15 7.1 Engine 132
7.1.1 Engine Barring manually 132
2.3 Engine layout 38
7.1.2 Engine Barring with starting system 134
2.4 Sensors, actuators and injectors on 12V
engines Overview 42 7.2 Cylinder Liner 135
2.5 Sensors, actuators and injectors on 16V 7.2.1 Cylinder liner Endoscopic examination 135
engines Overview 52 7.2.2 Instructions and comments on endoscopic and
visual examination of cylinder liners 137
3 Technical Data 7.3 Valve Drive 139

7.3.1 Valve gear Lubrication 139
3.1 12V 4000 M53R engine data 72 7.3.2 Valve clearance Check and adjustment 140
3.2 16V 4000 M53R engine data 76 7.3.3 Cylinder head cover Removal and
3.3 Engine Main dimensions 80 installation 143
3.4 Firing order 82
7.4 Injection Pump / HP Pump 144
7.4.1 HP pump Filling with engine oil 144
4 Operation 7.4.2 HP pump Relief bore check 145
4.1 Controls 83 7.5 Injection Valve / Injector 146

4.2 Putting the engine into operation after 7.5.1 Injector Replacement 146
extended out-of-service periods (>3 months) 84 7.5.2 Injector Removal and installation 147
4.3 Putting the engine into operation after 7.6 Fuel Filter 152
scheduled out-of-service-period 85 7.6.1 Supplementary fuel filter Overview 152
4.4 Starting the engine 86 7.6.2 Additional fuel filter Replacement 153
4.5 Operational checks 87 7.6.3 Fuel filter Replacement 154
4.6 Tasks after extended out-of-service periods 7.6.4 Fuel prefilter Differential pressure check
(>3 weeks) 88 and adjustment of gauge 156
4.7 Checks prior to start-up 89 7.6.5 Fuel prefilter Draining 157
7.6.6 Fuel prefilter Flushing 159
4.8 Fuel treatment system Putting into
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7.6.7 Fuel prefilter with water separator Filter

operation 90
element replacement 161
4.9 Fuel treatment system Switching on 93
4.10 Fuel treatment system Shutdown 94 7.7 Exhaust Turbocharger 163
4.11 Stopping the engine 95 7.7.1 Compressor wheel Cleaning 163
4.12 Emergency engine stop 96 7.8 Charge-Air Cooling 171
4.13 After stopping the engine 97 7.8.1 Charge-air cooler Checking condensate drain
4.14 Plant Cleaning 98 for water discharge and obstruction 171
7.9 Air Filter 172
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7.9.1 Air filter Replacement 172
7.9.2 Air filter Removal and installation 173
7.18 Auxiliary PTO 208
7.18.1 Bilge pump Relief bore check 208
7.10 Air Intake 174
7.10.1 Service indicator Signal ring position check
7.19 Fuel Supply System 209
7.19.1 Water drain valve Check 209
(optional) 174
7.19.2 Differential pressure gauge Check 210
7.11 Starting Equipment 175 7.19.3 Water level probe (3-in-1 rod electrode)
7.11.1 Starter Condition check 175 Check 211
7.19.4 Pump capacity Check 212
7.12 Lube Oil System, Lube Oil Circuit 176 7.19.5 Coalescer filter element Replacement 213
7.12.1 Engine oil Level check 176
7.12.2 Engine oil Change 177 7.20 Wiring (General) for Engine/Gearbox/Unit 215
7.12.3 Engine oil Sample extraction and analysis 179 7.20.1 Engine wiring harness Overview 215
7.20.2 Engine wiring Check 224
7.13 Oil Filtration / Cooling 181
7.13.1 Checking oil indicator filter 181 7.21 Accessories for (Electronic) Engine
7.13.2 Engine oil filter Replacement 183 Governor / Control System 225
7.13.3 Centrifugal oil filter Cleaning and filter 7.21.1 Limit switch for start interlock Check 225
sleeve replacement 185 7.21.2 Engine Control Unit ECU 7 Checking plug
connections 226
7.14 Coolant Circuit, General, High-Temperature
7.21.3 Engine monitoring unit EMU Plug
Circuit 188 connection check 227
7.14.1 Drain and vent points 188
7.21.4 Interface module EIM plug connections
7.14.2 Engine coolant level Check 192
Check 228
7.14.3 Engine coolant Change 193
7.21.5 Engine Control Unit ECU 7 Removal and
7.14.4 Engine coolant Draining 194
installation 229
7.14.5 Engine coolant Filling 197
7.21.6 EMU 7 Removal and installation 230
7.14.6 HT coolant pump Relief bore check 199
7.21.7 Engine Interface Module EIM Removal and
7.14.7 Engine coolant Sample extraction and
installation 231
analysis 200
7.21.8 Diagnostic features of EIM 232
7.14.8 Engine coolant filter Replacement 201
7.21.9 CDC parameters Reset 235
7.14.9 Preheating unit 202
7.15 Raw Water Pump with Connections 205

7.15.1 Raw water pump Relief bore check 205
8 Appendix A
7.16 Battery-Charging Generator 206 8.1 Abbreviations 236

7.16.1 Battery-charging generator drive Coupling 8.2 MTU contact persons/service partners 238
condition check 206
7.17 Engine Mounting / Support 207 9 Appendix B

7.17.1 Engine mounting Checking securing screws
9.1 Special Tools 239
for firm seating 207
9.2 Index 246
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1 Safety
1.1 Important provisions for all products
Nameplate
The product is identified by nameplate, model designation or serial number and must match with the
information on the title page of this manual.
Nameplate, model designation or serial number can be found on the product.
General information
This product may pose a risk of injury or damage in the following cases:
Incorrect use
Operation, maintenance and repair by unqualified personnel
Modifications or conversions
Noncompliance with the safety instructions and warning notices
Correct use
The product is intended exclusively for the application specified in the contract or defined at the time of
delivery.
This means that the equipment must be operated:
Within the permissible operating parameters in accordance with the ( Technical data)
With fluids and lubricants approved by the manufacturer in accordance with the ( Fluids and Lubri-
cants Specifications of the manufacturer)
With spare parts approved by the manufacturer in accordance with the ( Spare Parts Catalog/MTU
contact/Service partner)
In the original as-delivered configuration or in a configuration approved by the manufacturer in writ-
ing (including engine control/parameters)
In compliance with all safety regulations and in adherence with all warning notices in this manual
In accordance with the maintenance requirements over the entire service life of the product ( Main-
tenance Schedule)
In compliance with the maintenance and repair instructions contained in this manual, in particular
with regard to the specified tightening torques
With the exclusive use of technical personnel trained in commissioning, operation, maintenance and
repair
By contracting only workshops authorized by the manufacturer to carry out repair and overhaul
Any other use is considered improper use and increases the risk of personnel injury or material damage
in product operation. The manufacturer will accept no liability for such damage.
Modifications or conversions
Unauthorized modifications to the product compromise safety.
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The manufacturer will accept no liability or warranty claims for any damage caused by unauthorized
modifications or conversions.
Spare parts
Only genuine spare parts must be used to replace components or assemblies.
The manufacturer will accept no liability or warranty claims for any damage caused by the use of other
spare parts.
MS150036/02E 2013-11 | Safety | 5

1.2 Personnel and organizational requirements
Organizational measures of the operator
This manual must be issued to all personnel involved in operation, maintenance, repair or transporta-
tion.
Keep this manual handy in the vicinity of the product such that it is accessible to operating, mainte-
nance, repair and transport personnel at all times.
Use this manual as a basis for instructing personnel on product operation and repair, whereby the safe-
ty-relevant instructions, in particular, must be read and understood.
This is particularly important in the case of personnel who only occasionally perform work on or around
the product. This personnel must be instructed repeatedly.
Personnel requirements
All work on the product shall be carried out by trained and qualified personnel only.
Training at the Training Center of the manufacturer
Qualified personnel specialized in mechanical and plant engineering
The operator must define the responsibilities of the personnel involved in operation, maintenance, re-
pair and transport.
Working clothes and personal protective equipment

Wear proper protective clothing for all work.
When working, always wear the necessary personal protective equipment (e.g. ear protectors, protec-
tive gloves, goggles, breathing protection). Observe the information on personal protective equipment
in the respective activity description.
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6 | Safety | MS150036/02E 2013-11

1.3 Transport
Transport
Only use the lifting eyes provided to lift the engine.

The lifting eyes are designed for the transport of engine only, not for the transport of drive units (engine
and transmission).
Only use transport and lifting devices approved by MTU.
The engine must only be transported in installation position, max. permissible diagonal pull 10.
Take the engine's center of gravity into account.
In the case of special packaging with aluminum foil, suspend the engine on the lifting eyes of the trans-
port pallet or transport with equipment for heavy loads (forklift truck).
Install the crankshaft locking device and the locking screws for the engine mounts prior to engine trans-
portation.
Secure the engine against tilting during transport. The engine must be especially secured against slip-
ping or tilting when going up or down inclines and ramps.
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Setting the engine down after transport

Only set down engine on a firm, level surface.
Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.
Never place an engine on the oil pan, unless expressively authorized by MTU on a case-to-case basis to
do so.
MS150036/02E 2013-11 | Safety | 7

1.4 Safety regulations for maintenance and repair work
Safety regulations prior to maintenance and repair work
Have maintenance or repair work carried out by qualified and authorized personnel only.
Allow the product to cool down to less than 50C before starting maintenance work (risk of explosion
of oil vapors, fluids and lubricants, risk of burning).
Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Use
suitable containers of adequate capacity to catch fluids and lubricants.
When changing the oil or working on the fuel system, ensure that the service room is adequately venti-
lated.
Never carry out maintenance and repair work with the product in operation, unless:
Expressly permitted to do so following a written procedure.
The product is running in the low load range and only for as long as absolutely necessary.
Secure the product against unintentional starting, e.g. with start interlock.
Attach Do not operate sign in the operating area or to control equipment.
Disconnect the battery. Lock contactors.
Close the main valve on the compressed-air system and vent the compressed-air line when pneumatic
starters are fitted.
Disconnect the control equipment from the product.
The following applies to starters with copper-beryllium alloy pinions:
Wear breathing protection of filter class P3 during maintenance work. Do not blow out the interior of
the flywheel housing or the starter with compressed air. Clean the flywheel housing inside with a
class H dust extraction device.
Observe the safety data sheet.
Safety regulations during maintenance and repair work

Take special care when removing ventilation or plug screws from the product. Cover the screw or plug
with a rag to prevent fluids escaping under pressure.
Take care when draining hot fluids and lubricants (risk of burning).
Use only proper and calibrated tools. Observe the specified tightening torques during assembly or dis-
assembly.
Carry out work only on assemblies or plants which are properly secured.
Never use lines for climbing.
Keep fuel injection lines and connections clean.
Always seal connections with caps or covers if a line is removed or opened.
Take care not to damage lines, in particular fuel lines, during maintenance and repair work.
Ensure that all retainers and dampers are installed correctly.
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Ensure that all fuel injection and pressurized oil lines are installed with enough clearance to prevent
contact with other components. Do not place fuel or oil lines near hot components.
Do not touch elastomeric seals if they have carbonized or resinous appearance unless hands are prop-
erly protected.
Note cooling time for components which are heated for installation or removal (risk of burning).
When working high on the equipment, always use suitable ladders and work platforms. Make sure com-
ponents or assemblies are placed on stable surfaces.
8 | Safety | MS150036/02E 2013-11

Ensure particular cleanness during maintenance and repair work on the product. After completion of
maintenance and repair work, make sure that no unattached parts are in/on the product (e.g. cloths
and cable ties).
Safety regulations after completion of maintenance and repair work

Before barring, make sure that nobody is standing in the danger zone of the product.
Check that all guards have been reinstalled and that all tools and loose parts have been removed after
working on the product (in particular, the barring tool).
Welding work
Welding operations on the product or mounted units are not permitted. Cover the product when weld-
ing in its vicinity.
Before starting welding work:
Switch off the power supply master switch.
Disconnect the battery.
Separate the electrical ground of electronic equipment from the ground of the unit.
No other maintenance or repair work must be carried out in the vicinity of the product while welding is
going on. Risk of explosion or fire due to oil vapors and highly flammable fluids and lubricants.
Do not use product as ground terminal.
Never position the welding power supply cable adjacent to, or crossing wiring harnesses of the product.
The welding current may otherwise induce an interference voltage in the wiring harnesses which could
conceivably damage the electrical system.
Remove parts (e.g. exhaust pipes) which are to be welded from the product beforehand.
Hydraulic installation and removal

Check satisfactory function and safe operating condition of tools, jigs and fixtures to be used. Use only
the specified jigs and fixtures for hydraulic removal/installation procedures.
Observe the max. permissible force-on pressure specified for the jig/fixture.
Do not attempt to bend or apply force to lines.
Before starting work, pay attention to the following:
Vent the hydraulic installation/removal jig, the pumps and the lines at the relevant points for the
equipment to be used (e.g. open vent plugs, pump until bubble-free air emerges, close vent plugs).
For hydraulic installation, screw on the jig with the piston retracted.
For hydraulic removal, screw on the jig with the piston extended.
For a hydraulic installation/removal jig with central expansion pressure supply, screw spindle into shaft
end until correct sealing is established.
During hydraulic installation and removal, ensure that nobody is standing in the immediate vicinity of
the component to be installed/removed.
Working with batteries

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Observe the safety instructions of the battery manufacturer when working with batteries.
Gases emanating from the battery are explosive. Avoid sparks and naked flames.
Do not allow electrolyte to come in contact with skin or clothing.
Wear goggles and protective gloves.
Never place tools on the battery.
Before connecting the cable to the battery, check the battery polarity. Battery pole reversal may lead to
injury through the sudden discharge of acid or bursting of the battery body.
MS150036/02E 2013-11 | Safety | 9

Working on electrical and electronic assemblies
Always obtain the permission of the person in charge before commencing maintenance and repair work
or switching off any part of the electronic system required to do so.
De-energize the appropriate areas prior to working on assemblies.
Do not damage cabling during removal work. When reinstalling ensure that wiring is not damaged dur-
ing operation by contact with sharp objects, by rubbing against other components or by a hot surface.
Do not secure cables on lines carrying fluids.
Do not use cable straps to secure cables.
Always use connector pliers to tighten union nuts on connectors.
Subject the device as well as the product to a function check on completion of all repair work. In partic-
ular, check the function of the engine emergency stop feature.
Store spare parts properly prior to replacement, i.e. protect them against moisture in particular. Pack
defective electronic components and assemblies in a suitable manner when dispatched for repair, i.e.
protected, in particular, against moisture and impact and wrapped in antistatic foil if necessary.
Working with laser equipment

When working with laser equipment, always wear special laser-protection goggles (hazard due to heavi-
ly focused radiation).
Laser equipment must be equipped with the protective devices necessary for safe operation according
to type and application.
For conducting light-beam procedures and measurement work, only the following laser devices must be
used:
Laser devices of classes 1, 2 or 3A.
Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700
nm), a maximum output of 5 mW, and in which the beam axis and surface are designed to prevent
any risk to the eyes.
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10 | Safety | MS150036/02E 2013-11

1.5 Fire prevention and environmental protection, fluids and
lubricants, auxiliary materials
Fire prevention
Rectify any fuel or oil leaks immediately. Oil or fuel on hot components can cause fires therefore al-
ways keep the product in a clean condition. Do not leave rags saturated with fluids and lubricants on
the product. Do not store combustible materials near the product.
Do not carry out welding work on pipes and components carrying oil or fuel. Before welding, clean with
a nonflammable fluid.
When starting the engine with an external power source, connect the ground lead last and remove it
first. To avoid sparks in the vicinity of the battery, connect the ground lead from the external power
source to the ground lead of the engine or to the ground terminal of the starter.
Always keep suitable firefighting equipment (fire extinguishers) at hand and familiarize yourself with
their use.
Noise
Noise can lead to an increased risk of accidents if it makes it more difficult to hear audible signals,
warning calls or noises indicating danger.
Wear ear protectors in workplaces with a sound pressure level in excess of 85dB (A).
Environmental protection and disposal

Modification or removal of any mechanical/electronic components or the installation of additional com-
ponents including the execution of calibration processes that might affect the emission characteristics
of the product are prohibited by emission regulations. Emission control units/systems may only be
maintained, exchanged or repaired if the components used for this purpose are approved by the manu-
facturer. Noncompliance with these guidelines will invalidate the design type approval issued by the
emissions regulation authorities. The manufacturer does not accept any liability for violations of the
emission regulations. The maintenance schedules of the manufacturer must be observed over the entire
life cycle of the product.
Dispose of used fluids, lubricants and filters in accordance with local regulations.
Within the EU, batteries can be returned free of charge to the manufacturer where they will be properly
recycled.
Consumable fluids and materials

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to opera-
tion, make sure that the latest version is used. The latest version can be found on the website on the
"Technical Info" or "Spare Parts and Service" tabs at http://www.mtu-online.com.
Consumable fluids and materials may also be hazardous or toxic. When using fluids, lubricants, consum-
ables and other chemical substances, follow the safety regulations that apply to the product. Take spe-
cial care when using hot, chilled or caustic substances. When using flammable materials, prevent them
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coming into contact with ignition sources and do not smoke.
Used oil
Used oil contains combustion residues that are harmful to health.
Rub barrier cream into hands.
Wash hands after contact with used oil.
MS150036/02E 2013-11 | Safety | 11

Lead
Adopt suitable measures to avoid the formation of lead dust.
Switch on extraction system.
When working with lead or pastes that contain lead, avoid direct contact with the skin. Do not inhale
lead vapors.
Wash hands after contact with lead or lead-containing substances.
Compressed air
Observe special safety precautions when working with compressed air:
Unauthorized use of compressed air, e.g. forcing flammable liquids (hazard class AI, AII and B) out of
containers, risks causing an explosion.
Wear goggles when blowing dirt off workpieces or blowing away swarf.
Blowing compressed air into thin-walled containers (e.g. containers made of sheet metal, plastic or
glass) for drying purposes or to check for leaks risks bursting them.
Pay special attention to the pressure in the compressed air system or pressure vessel.
Assemblies or products to be connected must either be designed for that pressure, or, if the permis-
sible pressure is lower than the system pressure, a pressure reducing valve and safety valve (set to
the permissible pressure) must be connected between the assemblies/products and the system.
Hose couplings and connections must be securely attached.
Provide the snout of the air nozzle with a protective disk (e.g. rubber disk).
First shut off compressed air lines before compressed air device is disconnected from the supply
line, or before device or tool is to be replaced.
Carry out leak test in accordance with the specifications.
Paints and varnishes

Observe the relevant safety data sheet for all materials.
When painting in areas other than spray booths equipped with extractors, ensure good ventilation.
Make sure that neighboring work areas are not adversely affected.
There must be no naked flames in the vicinity.
No smoking.
Observe fire prevention regulations.
Always wear a mask providing protection against paint and solvent vapors.
Liquid nitrogen
Store liquid nitrogen only in small quantities and always in regulation containers (without gas-tight
caps).
Avoid body contact (eyes, hands).
Wear protective clothing, protective gloves, closed shoes and safety goggles.
Make sure that working area is well ventilated.
Avoid knocking or jolting the containers, valves and fittings or workpieces in any way.
Acids/alkaline solutions/urea (AdBlue, DEF)

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When working with acids and alkaline solutions, wear goggles or face mask, gloves and protective
clothing.
Do not inhale vapors.
If urea solution is swallowed, rinse out mouth and drink plenty of water.
If spilled onto clothing, remove the affected clothing immediately.
After contact with skin, rinse affected parts of the body with plenty of water.
Rinse eyes immediately with eyedrops or clean tap water. Seek medical attention as soon as possi-
ble.
12 | Safety | MS150036/02E 2013-11

1.6 Standards for safety notices in the text
DANGER
In the event of immediate danger.
Consequences: Death, serious or permanent injury!
Remedial action.
WARNING
In the event of a situation involving potential danger.
Consequences: Death, serious or permanent injury!
Remedial action.
CAUTION
In the event of a situation involving potential danger.
Consequences: Minor or moderate injuries!
Remedial action.
NOTICE
In the event of a situation involving potentially adverse effects on the product.
Consequences: Material damage!
Remedial action.
Additional product information.
Safety notices
u This manual with all safety instructions and safety notices must be issued to all personnel involved in
operation, maintenance, repair or transportation.
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MS150036/02E 2013-11 | Safety | 13

2 General Information
2.1 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS) (4).
For designation of the cylinders (to DIN ISO 1204) the letter "A" (1) is used to refer to the cylinders on
the left-hand side of the engine and the letter "B" (3) to refer to the cylinders on the right-hand side. The
cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
The numbering of other engine components also starts with no. 1 at the driving end.
1 Left-hand side of engine 3 Right-hand side of engine

2 Free end 4 Driving end
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14 | General Information | MS150036/02E 2013-11

2.2 Product description
Description of the engine
Engine
The engine is a liquid-cooled four-stroke diesel engine, rotating counterclockwise (seen from driving
end), with direct injection, sequential turbocharging and charge air cooling.
The engine is monitored by an engine control and monitoring system (ADEC).
Fuel system
Electronically controlled common-rail-injection system with HP pump, pressure accumulator (rail) and
single injectors with integrated individual store.
The electronic control unit controls
Injection start
Injection quantity
Injection pressure
Exhaust system
The exhaust system is equipped with triple-walled, water-cooled exhaust lines.
The triple-walled design permits
low surface temperature,
reduced amount of heat to be dissipated by the coolant,
absolute gas-tightness.
Turbocharging
Sequential turbocharging with internal, engine-coolant-controlled charge air cooling. The right-hand ex-
haust turbocharger is cut-in and cut-out on 12V and 16V engines with electronically-controlled, hydraul-
ically-actuated flaps.
Cooling system
Split-circuit engine coolant system with remote or engine-mounted heat exchanger.
Heating of the charge air in idle and low-load operation prevents white smoke formation.
Seawater flows only through engine coolant cooler and fuel cooler as well as the raw water pump (if
fitted).
Service block
The service components are mounted at the auxiliary PTO end.
The layout permits easy access for maintenance.
Service-components:
Raw-water pump (if fitted), coolant pump
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Centrifugal lube oil filter

Coolant expansion tank (only on engines with engine-mounted heat exchanger)
Coolant filter
Electronic system
Electronic control and monitoring system with integrated security and test system with interfaces to
remote control system (RCS) and to monitoring system (MCS).
MS150036/02E 2013-11 | General Information | 15

Engine Interface Module (EIM)
The Engine Interface Module (EIM) is the central connection box on the engine. It covers the complete
minimum scope of a marine engine. It does not comprise control elements of components requiring
maintenance.
Functions:
Starter control (start repetition, tooth alignment, starter protection)
Monitoring of the battery-charging generator
Open bus interface to the plant (SAE J1939)
Emergency stop function with line break monitoring
Redundant supply voltage input
Emergency shut-off flap control (option)
Key switch logic
Interface to ECU and EMU
MCS5 dialog interface
Control of an MTU lube-oil priming pump (power components in separate MTU PPC Box)
Connection facility for an MTU Local Operating Station (LOS)
Serial RS422 interface for diagnosis

The engine interface comprises two parts. The first part of signals is integrated in the engine wiring har-
ness with a 62-pole Tyco connector X52. The second part refers to signals associated with higher cur-
rents. These signals are led out via M threaded bolts and also integrated in the engine wiring harness.
Functions
ECU supply
EMU supply
Plant signals (ECU7 connector X1)
Bus interface (2x MCS5 CAN)
CAN dialog output (1xMCS5 CAN)
Emergency stop from EMU and ECU
Electric starter
Terminal 45 starter A/B (engaged)
Pneumatic starter
Starting-air pressure valve
Start-air pressure sensor
Barring gear (1 and 2)
Battery-charging generator (with exciter control)
Optional emergency air shut-off flaps
Activation signal to air shut-off flaps 1+2
Feedback signal from air shut-off flaps 1+2
Electronic engine governor (ECU)

Functions:
Engine speed control with fuel and speed limitation dependent on engine status and operating condi-
tions
Control of sequential turbocharging, cylinder bank cut-out and air recirculation function.
Data processing logistics for analog and binary signals
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Interface for data transfer to CAN field bus for remote control and ship-side monitoring
Electronic Engine Monitoring Unit (EMU)

Functions:
Data processing logistics for analog and binary signals
Interface for data transfer to CAN field bus for remote control and ship-side monitoring

Low-load operation
Performance diagram
1 Low-load operation 2 Cleaning cycle 3 ditto

MTU Series 4000M53R engines may be operated in low-load operation. State-of-the-art design and
equipment features, e.g. TE coolant circuit, sequential turbocharging, jacketed, coolant-cooled exhaust
lines, Common Rail fuel injection and cylinder cut-out allow engine operation at low load.
Nevertheless, low-load operation at engine load below 15% of the nominal rating is permitted for max.
100 hours. In order to avoid inadmissible oil carbon and/or carbon particle deposits in the engine, it is
recommended to carry out a cleaning cycle for at least 20 minutes after extended low-load operation
periods. During the cleaning cycle, engine speed (power) must be increased step by step until all turbo-
chargers are running. The figure shows the basic speed/power run-up procedure for the cleaning cycle
to be carried out.
SOLAS Fire protection specifications

Fuel system, fuel lines with fuel pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
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shown.

1 Fuel line after LP pump
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1 Fuel line to fuel filter head

retainer

1 Fuel line from fuel filter
head
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1 Fuel line on HP pump

1 Fuel line on fuel filter head
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1 Fuel line on fuel filter head

Lube oil system, oil lines with oil pressure >1.8 bar
All lines with SOLAS-compliant covers for pipe connections, according to MTU standard MTN5233, are
shown.
1 Oil supply for recirculation

valve
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1 Oil supply line on HP pump
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1 Oil supply line of HP pump
on equipment carrier
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1 Oil supply for actuating
cylinder of turbocharger
B1 exhaust flap
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1 Oil supply on equipment
carrier
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Engines with horizontal air intake
1 Oil supply for actuating 2 Oil supply for T-piece of

cylinder of turbocharger flap control
B1 air flap
TIM-ID: 0000045751 - 001

1 Oil supply to distributor 2 Oil return
TIM-ID: 0000045751 - 001

1 Oil return
TIM-ID: 0000045751 - 001

1 Oil line to flap control 3 Oil line from main oil gal-
2 Oil line to recirculation lery
valve 4 Oil line to ETC
TIM-ID: 0000045751 - 001

1 ETC oil supply 2 ETC oil supply
TIM-ID: 0000045751 - 001

Engines with vertical air intake
1 Oil supply for actuating 2 Oil supply for T-piece of 3 Oil supply for actuating
cylinder of turbocharger flap control cylinder of turbocharger
B1 air flap B1 air flap
TIM-ID: 0000045751 - 001

1 Oil supply to distributor of
flap control, B-side
TIM-ID: 0000045751 - 001
1 Oil lines for B-side flap 2 Oil lines for B-side flap
control from main oil gal- control to main oil gallery
lery

1 Oil supply for flap control
to main oil gallery in en-
gine Vee, engine free end
TIM-ID: 0000045751 - 001

1 Turbocharger oil supply
connection to main oil gal-
lery in engine Vee
TIM-ID: 0000045751 - 001

1 Oil supply on distribution
point of turbocharger oil
supply on engine free end
TIM-ID: 0000045751 - 001
1 Cover on oil filter cartridge

Special connections
In case of leakage, the following connection types are spray-protected even without a cover and have
been confirmed compliant with SOLAS by GL and DNV.
Plug-in pipe union

The sleeve (4) covers the joint to prevent lateral spray.
Only leak-off along the line is possible, the pressure is decreases significantly if an O-ring (3) defect
occurs.
TIM-ID: 0000045751 - 001
The connection is confirmed as compliant with SOLAS by DNV and GL.
Plugs and sensors

Screw-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,
or an O-ring (ISO).
In case of a loose thread or a defective sealing ring (2), the liquid first has to pass the thread.
The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not under
pressure.

HP connections
1 Jacket pipe 8 Thrust ring 15 Union nut

2 HP fuel line 9 Union nut 16 Thrust ring
3 O-ring 10 Union nut 17 HP line outer pipe
4 Union nut 11 Connecting piece 18 Internal pipe of HP line
5 Recess for O-ring 12 Snap ring 19 Ball-type seal area
6 Thrust ring 13 Thrust ring 20 Leak-fuel connection
7 Leakage overflow bore 14 Compensating disks
HP connections
The HP fuel line is sealed by the thrust ring (8).
If leakage in the area of the thrust ring (8) or the HP line (5) occurs, the emerging fuel is routed to the
leakage chamber.
The leaking fuel is drained off without pressure via the leakage overflow-bore (7). The leakage chamber
is sealed toward the outside by the O-rings (3).
This prevents leakage egress.
The connection is confirmed as compliant with SOLAS by DNV and GL.
TIM-ID: 0000045751 - 001

2.3 Engine layout
Engines with remote heat exchanger and horizontal air intake
1 Engine management and 10 Recirculation line 19 Battery-charging generator

monitoring 11 Exhaust manifold 20 HP fuel pump
2 Oil cooler 12 Engine mounts 21 Oil filter
3 Centrifugal oil filter 13 Charge-air line 22 Bilge pump (option)
4 Crankcase breather 14 Oil pan 23 Coolant outlet to remote
5 Dry-type air filter 15 Oil filler neck cooling system
6 Exhaust turbocharger 16 Crankcase 24 Coolant inlet from remote
7 Exhaust outlet 17 Cylinder head cooling system
8 Air pipe to charge-air cool- 18 Fuel filter KGS Free end
er
9 Charge-air cooler
TIM-ID: 0000009990 - 006

Engines with engine-mounted heat exchanger and horizontal air intake
1 Raw-water outlet 10 Exhaust outlet 19 Cylinder head

2 Engine management and 11 Air pipe to charge-air cool- 20 Crankcase
monitoring er 21 Fuel filter
3 Plate-core heat exchanger 12 Recirculation line 22 Battery-charging generator
4 Oil cooler 13 Exhaust manifold 23 HP fuel pump
5 Coolant expansion tank 14 Charge-air cooler 24 Oil filter
7 Crankcase breather 16 Engine mounts 26 Raw-water inlet
8 Dry-type air filter 17 Oil pan KGS Free end
9 Exhaust turbocharger 18 Oil filler neck
TIM-ID: 0000009990 - 006

Engines with remote heat exchanger and vertical air intake
1 Coolant outlet to remote 10 Exhaust turbocharger 19 Cylinder head

cooling system 11 Exhaust outlet 20 Fuel filter
2 Coolant inlet from remote 12 Air pipe to charge-air cool- 21 Oil filter
cooling system er 22 HP fuel pump
3 Engine management and 13 Charge-air cooler 23 Battery-charging generator
monitoring 14 Engine mounts 24 Bilge pump (option)
4 Oil cooler 15 Charge-air line KGS Free end
5 Centrifugal oil filter 16 Oil pan
6 Crankcase breather 17 Oil filler neck
7 Dry-type air filter 18 Crankcase
8 Exhaust manifold
9 Recirculation line
Illustration is also valid for 16V engines.
TIM-ID: 0000009990 - 006

Engines with engine-mounted heat exchanger and vertical air intake
1 Raw-water outlet 10 Recirculation line 19 Crankcase

2 Engine management and 11 Exhaust turbocharger 20 Cylinder head
monitoring 12 Exhaust outlet 21 Fuel filter
3 Oil cooler 13 Air pipe to charge-air cool- 22 Oil filter
4 Plate-core heat exchanger er 23 HP fuel pump
5 Coolant expansion tank 14 Charge-air cooler 24 Battery-charging generator
7 Crankcase breather 16 Engine mounts 26 Raw-water inlet
8 Dry-type air filter 17 Oil pan KGS Free end
9 Exhaust manifold 18 Oil filler neck
Illustration is also valid for 16V engines.
Engine model designation

Key to the engine model designations 12/16V 4000 Mxy z
12, 16 Number of cylinders
V Cylinder arrangement: V-engine
4000 Series
TIM-ID: 0000009990 - 006
M Application (M= Marine)

x Application load profile (0, 1, 2, 3...9)
y Design index (0, 1, 2, 3...9)
z R (power / speed reduction)
L (enhanced power / speed)
S (60 Hz)
F (50 Hz)

2.4 Sensors, actuators and injectors on 12V engines Overview
Engines with vertical air intake, remote heat exchanger
12 V 4000 M engine, left engine side
1 B49/Y26 (charge-air tem- 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after
perature before recircula- 5 B34.3 (fuel pressure be- filter)
tion valve)/(recirculation fore filter) (only if supple- 8 F46 (leak fuel level)
valve A) mentary fuel filter is fitted)
2 B3 (intake air temperature) 6 B34.2 (fuel pressure be-
3 B44.1 (turbocharger A fore filter)
speed)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, free end
1 B7 (lube oil temperature) 4 B33 (fuel temperature in 7 B54 (oil refill pump pres-
2 B5.3 (lube-oil pressure be- common rail) sure) (optional)
fore filter) 5 B48 (fuel pressure in com- 8 B6.2 (coolant tempera-
3 B5.1 (lube-oil pressure af- mon rail) ture) (optional)
ter filter) 6 B1 (camshaft speed) 9 B6 (coolant temperature)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, right engine side
1 B44.2 (turbocharger B 3 B16 (coolant pressure)

speed) 4 B9 (charge-air tempera-
2 Y27 (turbocharger control ture)
valve)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, driving end
1 B4.22 (exhaust tempera- 3 S37.2 (safety switch) 5 B13.2 (crankshaft speed)

ture, B bank) 4 S37.1 (safety switch) (optional)
2 B13 (crankshaft speed) 6 B4.21 (exhaust tempera-
ture, a bank)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, top view
1 B4 (cylinder exhaust tem- 2 B50 (crankcase pressure) 3 B33 (alternatively) (fuel

perature A1-A6, B1-B6) temperature in common
(optional) rail)
TIM-ID: 0000012941 - 003

Engines with vertical air intake, engine-mounted heat exchanger
12 V 4000 M engine, left engine side
1 B49/Y26 (charge-air tem- 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after
perature before recircula- 5 B34.3 (fuel pressure be- filter)
tion valve)/(recirculation fore filter) (only if supple- 8 F46 (leak fuel level)
valve A) mentary fuel filter is fitted)
2 B3 (intake air temperature) 6 B34.2 (fuel pressure be-
3 B44.1 (turbocharger A fore filter)
speed)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, free end
TIM-ID: 0000012941 - 003

12 V 4000 M engine, right engine side
1 B44.2 (turbocharger B 3 B16 (coolant pressure) 5 B9 (charge-air tempera-

speed) 4 B21 (raw-water pressure) ture)
2 Y27 (turbocharger control (optional)
valve)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, driving end

ture, a bank)
TIM-ID: 0000012941 - 003

12 V 4000 M engine, top view
1 B4 (cylinder exhaust tem- 3 B33 (alternatively) (fuel

(optional) rail)
2 B50 (crankcase pressure) 4 F33 (coolant level)
TIM-ID: 0000012941 - 003

2.5 Sensors, actuators and injectors on 16V engines Overview
Engines with horizontal air intake, remote heat exchanger
16V 4000 M engine, left engine side
1 B50 (crankcase pressure) 4 B10 (charge-air pressure) 7 B34.1 (fuel pressure after
2 B3 (intake air temperature) 5 B34.3 (fuel pressure be- filter)
3 B44.1 (turbocharger A fore filter) (only if supple- 8 F46 (leak fuel level)
speed) mentary fuel filter is fitted)
6 B34.2 (fuel pressure be-
fore filter) TIM-ID: 0000018445 - 003

16V 4000 M engine, free end
2 B5.3 (lube oil pressure be- common rail) sure) (optional)
3 B5.1 (lube oil pressure af- mon rail) ture) (optional)
TIM-ID: 0000018445 - 003

16V 4000 M engine, right engine side

valve)
TIM-ID: 0000018445 - 003

16V 4000 M engine, driving end

ture, a bank)
TIM-ID: 0000018445 - 003

16V 4000 M engine, engine top
1 B49/Y26 (charge-air tem- 2 B4 (cylinder exhaust tem- 3 B33 (alternatively) (fuel

perature before recircula- perature A1-A6, B1-B8) temperature in common
tion valve)/(recirculation (optional) rail)
valve A)
TIM-ID: 0000018445 - 003

Engines with horizontal air intake, engine-mounted heat exchanger
1 B50 (crankcase pressure) 4 B3 (intake air temperature) 7 B34.2 (fuel pressure be-
2 B49/Y26 (charge-air tem- 5 B10 (charge-air pressure) fore filter)
perature before recircula- 6 B34.3 (fuel pressure be- 8 B34.1 (fuel pressure after
tion valve)/(recirculation fore filter) (only if supple- filter)
valve A) mentary fuel filter is fitted) 9 F46 (leak fuel level)
3 B44.1 (turbocharger A
speed)
TIM-ID: 0000018445 - 003

2 B5.3 (lube oil pressure be- common rail) sure) (optional)
3 B5.1 (lube oil pressure af- mon rail) ture) (optional)
TIM-ID: 0000018445 - 003


valve)
TIM-ID: 0000018445 - 003


ture, a bank)
TIM-ID: 0000018445 - 003

1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel 3 F33 (coolant level)

(optional) rail)
TIM-ID: 0000018445 - 003

Engines with vertical air intake, remote heat exchanger
1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure be-

2 B49/Y26 (charge-air tem- speed) fore filter)
perature before recircula- 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure after
tion valve)/(recirculation 6 B34.3 (fuel pressure be- filter)
valve A) fore filter) (only if supple- 9 F46 (leak fuel level)
3 B3 (intake air temperature) mentary fuel filter is fitted)
TIM-ID: 0000018445 - 003

TIM-ID: 0000018445 - 003


valve)
TIM-ID: 0000018445 - 003


ture, a bank)
TIM-ID: 0000018445 - 003

1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel

(optional) rail)
TIM-ID: 0000018445 - 003

Engines with vertical air intake, engine-mounted heat exchanger
1 B50 (crankcase pressure) 4 B44.1 (turbocharger A 7 B34.2 (fuel pressure be-

2 B49/Y26 (charge-air tem- speed) fore filter)
perature before recircula- 5 B10 (charge-air pressure) 8 B34.1 (fuel pressure after
tion valve)/(recirculation 6 B34.3 (fuel pressure be- filter)
valve A) fore filter) (only if supple- 9 F46 (leak fuel level)
3 B3 (intake air temperature) mentary fuel filter is fitted)
TIM-ID: 0000018445 - 003

TIM-ID: 0000018445 - 003


valve)
TIM-ID: 0000018445 - 003


ture, a bank)
TIM-ID: 0000018445 - 003

1 B4 (cylinder exhaust tem- 2 B33 (alternatively) (fuel 3 F33 (coolant level)

(optional) rail)
TIM-ID: 0000018445 - 003

3 Technical Data
3.1 12V 4000 M53R engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
r Guideline value
L Limit up to which the engine can be operated without changes, e.g. power setting
N Not yet defined value
- Not applicable
X Applicable
* Not yet verified value
ENGINE DATA
Engine model 12V 4000 M53R 12V 4000 M53R
Engine-mounted Remote heat ex-
heat exchanger changer
Application group 1A 1A 1A 1A
Intake air temperature C 25 45 25 45
Charge air coolant temperature C - - - -
Raw water inlet temperature C 25 32 25 32
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Rated engine speed A rpm 1600 1600 1600 1600
Fuel stop power ISO 3046 A kW 1140 1140 1140 1140
GENERAL CONDITIONS (for maximum power)

TIM-ID: 0000010786 - 002
Intake depression (new filter) A mbar 15 15 15 15

Intake depression, max. L mbar 30 30 30 30
72 | Technical Data | MS150036/02E 2013-11

MODEL RELATED DATA (basic design)
Cylinder arrangement: V angle Degrees 90 90 90 90
()
Bore mm 170 170 170 170
Stroke mm 210 210 210 210
Displacement, cylinder Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 57.2 57.2 57.2 57.2
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2
RAW WATER CIRCUIT (open circuit)

Raw water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: Inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in off-engine raw-water sys- L bar 1.0 1.0 -- --
tem, max.
LUBE OIL SYSTEM

Lube oil operating temperature before en- r C 81 82 81 82
gine, from
gine, to
Lube oil operating pressure before engine, r bar 5.1 5.1 5.1 5.1
from
to
Lube oil operating pressure (low idle) r bar 2.5 2.5 2.5 2.5
(meas. point: before engine)
FUEL SYSTEM
TIM-ID: 0000010786 - 002

Fuel pressure at engine inlet connection, L bar -0.1 -0.1 -0.1 -0.1
min. (when engine is starting)
min. (when engine is running),
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
MS150036/02E 2013-11 | Technical Data | 73

GENERAL OPERATING DATA
Firing speed, from r rpm 80 80 80 80
Firing speed, to r rpm 120 120 120 120
STARTER (electric)
Rated starter voltage (standard design) r V= 24 24 24 24
STARTER (pneumatic / hydraulic)

Starting air pressure before starter motor, r bar 8 8 8 8
min.
max.
INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Longitudinal inclination, continuous max., L Degrees 15 15 15 15
driving end down (Option: max. operating ()
inclinations)
Longitudinal inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
driving end down (option: max. operating ()
inclinations)
Longitudinal inclination, continuous max. L Degrees 10 10 10 10
driving end up (option: max. operating in- ()
clinations)
Transverse inclination continuous max. L Degrees 22.5 22.5 22.5 22.5
(Option: max. operating inclinations) ()
CAPACITIES
TIM-ID: 0000010786 - 002

Engine coolant capacity, engine side (with r Liters 305 305 -- --
cooling equipment)
Engine oil capacity, initial filling (standard r Liters 265 265 265 265
oil system) (Option: max. operating incli-
nations)

Oil pan capacity dipstick mark min. L Liters 195 195 195 195
(standard oil system) (design: max. oper-
ating inclinations)
Oil pan capacity dipstick mark max. L Liters 235 235 235 235
ating inclinations)
WEIGHTS / MAIN DIMENSIONS

Engine dry weight (with mounted standard r kg 7640 7640 7240 7240
accessories, w/o coupling)
NOISE
Exhaust noise, unsilenced, BL (free-field r dB(A) 108* 108* 108* 108*
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- r dB(A) 102* 102* 102* 102*
take noise (filter), BL, (free-field sound-
pressure level Lp, 1m distance, ISO
6798+2dB(A) tolerance)
TIM-ID: 0000010786 - 002

3.2 16V 4000 M53R engine data
Explanation:
DL Ref. value: Continuous power
BL Ref. value: Fuel stop power
A Design value
G Guaranteed value
r Guideline value
L Limit up to which the engine can be operated without changes, e.g. power setting
N Not yet defined value
- Not applicable
X Applicable
Heat exchanger Heat exchanger

engine-mounted remote
Application group 1A 1A 1A 1A
Intake air temperature C 25 45 25 45
Charge air coolant temperature C - - - -
Raw water inlet temperature C 25 32 25 32
Barometric pressure mbar 1000 1000 1000 1000
Site altitude above sea level M 100 100 100 100
POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)
Rated engine speed A rpm 1600 1600 1600 1600
Fuel stop power ISO 3046 A kW 1520 1520 1520 1520
GENERAL CONDITIONS (for maximum power)

Intake depression (new filter) A mbar 15 15 15 15
Intake depression, max. L mbar 30 30 30 30
MODEL RELATED DATA (basic design)

Cylinder arrangement: V angle Degrees 90 90 90 90
()
TIM-ID: 0000010854 - 002
Bore mm 170 170 170 170

Stroke mm 210 210 210 210
Displacement, cylinder Liters 4.77 4.77 4.77 4.77
Displacement, total Liters 76.3 76.3 76.3 76.3
Number of inlet valves per cylinder 2 2 2 2
Number of exhaust valves per cylinder 2 2 2 2

RAW WATER CIRCUIT (open circuit)
Raw water pump: Inlet pressure, min. L bar -0.4 -0.4 -- --
Raw water pump: Inlet pressure, max. L bar 1.0 1.0 -- --
Pressure loss in off-engine raw-water sys- L bar 1.0 1.0 -- --
tem, max.
LUBE OIL SYSTEM

gine, from
gine, to
from
to
Lube oil operating pressure (low idle) r bar 2.5 2.5 2.5 2.5
(meas. point: before engine)
FUEL SYSTEM
min. (when engine is starting)
min. (when engine is running),
Fuel pressure at engine inlet connection, L bar 1.5 1.5 1.5 1.5
max. (when engine is starting)
Fuel supply flow, max. A Liter/min
GENERAL OPERATING DATA

Firing speed, from r rpm 80 80 80 80
Firing speed, to r rpm 120 120 120 120
TIM-ID: 0000010854 - 002
STARTER (electric)
Rated starter voltage (standard design) r V= 24 24 24 24

STARTER (pneumatic / hydraulic)
min.
max.
INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)

Longitudinal inclination, continuous max., L Degrees 15 15 15 15
driving end down (Option: max. operating ()
inclinations)
Longitudinal inclination, temporary max. L Degrees 22.5 22.5 22.5 22.5
driving end down (option: max. operating ()
inclinations)
Longitudinal inclination, continuous max. L Degrees 10 10 10 10
clinations)
Longitudinal inclination, temporary max. L Degrees
clinations)
Transverse inclination continuous max. L Degrees 22.5 22.5 22.5 22.5
(Option: max. operating inclinations) ()
Transverse inclination, temporary max. L Degrees
(option: max. operating inclinations) ()
CAPACITIES
Engine coolant capacity, engine side (with r Liters 350 350 -- --
cooling equipment)
Engine oil capacity, initial filling (standard r Liters 280 280 280 280
oil system) (Option: max. operating incli-
nations)
Oil change quantity max. (standard oil sys- r Liters
tem) (design: max. operating inclinations)
Oil pan capacity dipstick mark min. L Liters 210 210 210 210
TIM-ID: 0000010854 - 002
ating inclinations)
Oil pan capacity dipstick mark max. L Liters 250 250 250 250
ating inclinations)

WEIGHTS / MAIN DIMENSIONS
Engine dry weight (with mounted standard r kg 9020 9020 8590 8590
accessories, w/o coupling)
NOISE
Exhaust noise, unsilenced, BL (free-field r dB(A) 109 109 109 109
sound pressure level Lp, 1m distance, ISO
6798, +3dB(A) tolerance)
Engine surface noise with attenuated in- r dB(A)
take noise (filter), BL, (free-field sound-
pressure level Lp, 1m distance, ISO
6798+2dB(A) tolerance)
TIM-ID: 0000010854 - 002

3.3 Engine Main dimensions
Engines with horizontal air intake

With remote heat exchanger
Engine model Length (A) Width (B) without Width (B) with si- Height (C)
silencer lencer
16V 4000 M53R approx. 3108 mm approx. 1690 mm approx. 1850 mm approx. 2064 mm
With engine-mounted heat exchanger

Engine model Length (A) Width (B) without Width (B) with si- Height (C)
TIM-ID: 0000045752 - 001
silencer lencer

Engines with vertical air intake
With remote heat exchanger
Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
With engine-mounted heat exchanger

Engine model Length (A) Width (B) Height (C) without Height (C) with si-
silencer lencer
TIM-ID: 0000045752 - 001

3.4 Firing order
Cylinders Firing order
12 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B1
16 V A1-A7-B4-B6-A4-B8-A2-A8-B3-B5-A3-A5-B2-A6-B1-B7
TIM-ID: 0000023263 - 002

4 Operation
4.1 Controls
Automation system controls
Refer to automation system operating instructions
TIM-ID: 0000016959 - 003
MS150036/02E 2013-11 | Operation | 83

4.2 Putting the engine into operation after extended out-of-service
periods (>3 months)
Preconditions
Engine is stopped and starting disabled.
MTU Preservation and Represervation Specifications (A001070/..) are available.
Putting the engine into operation after extended out-of-service-periods (>3

months)
Item Task
Engine Depreserve ( Preservation and Represervation Specifications A001070/..).
Lube oil system Check engine oil level ( Page 176);
Preheat engine oil if required.
Fuel prefilter Prime with fuel ( Page 161)
Fuel prefilter, pressure Align adjustable pointer with position of pressure indicator ( Page 156).
gauge
HP fuel pump Only for engines without oil priming pump:
Fill HP fuel pump with new engine oil ( Page 144).
Raw-water pump (if located Prime with water (approx. 3 4 l).
above waterline (only appli-
cable to engines with en-
gine-mounted heat exchang-
er or with optional remote
heat exchanger))
Coolant circuit If engine is out of service for more than one year, change engine coolant
( Page 193).
Coolant circuit Check coolant level ( Page 192).
Coolant circuit Preheat coolant with preheating unit.
Engine control system Refer to automation system operating instructions.
ECU Check plug connections ( Page 226).
EMU Check plug connections ( Page 227)
EIM Check plug connections ( Page 228).
TIM-ID: 0000010092 - 005
84 | Operation | MS150036/02E 2013-11

4.3 Putting the engine into operation after scheduled out-of-
service-period
Preconditions
Putting into operation

Item Task
Lube oil system Check engine oil level ( Page 176);
Preheat engine oil if required.
Coolant system Check coolant level ( Page 192).
Coolant system Preheat coolant with preheating unit.
Fuel prefilter Drain ( Page 157);
Check that suction-side pressure indicated at the fuel prefilter pressure
gauge is within the limit ( Page 156).
Engine control system Refer to automation system operating instructions.
ECU Check plug connections ( Page 226).
EIM Check plug connections ( Page 228).
EMU Check plug connections ( Page 227).
TIM-ID: 0000010655 - 004
MS150036/02E 2013-11 | Operation | 85

4.4 Starting the engine
Start the engine via the automation system
TIM-ID: 0000017525 - 003
86 | Operation | MS150036/02E 2013-11

4.5 Operational checks
DANGER
Rotating and moving engine parts.
Risk of crushing, danger of parts of the body being caught or pulled in!
Only run the engine at low power. Keep away from the engine's danger zone.
WARNING
High level of engine noise when the engine is running.
Risk of damage to hearing!
Wear ear protectors.
Operational checks
Item Measure
Engine under load Check engine visually for leaks and general condition; Check air pipework be-
Engine at nominal speed tween air filter and exhaust turbocharger for leaks and damage.
Check for abnormal running noise, vibration, and exhaust color ( Page 101).
Charge-air cooler Check condensate drain ( Page 171).
Air filter Check signal ring position of service indicator ( Page 174).
Replace air filter ( Page 172), if the signal ring is completely visible in the
service indicator control window.
HP fuel pump Check relief bores for fuel discharge ( Page 145).
HT coolant pump Check relief bore for oil and coolant discharge and obstructions
( Page 199).
Fuel prefilter (optional) Check reading on differential pressure gauge ( Page 174);
Drain water and contaminants ( Page 159).
Raw water pump (only on Check relief bore for oil and coolant discharge and obstructions
engines with engine-mount- ( Page 205).
ed or optional remote heat
exchanger)
Bilge pump (optional) Check relief bore for oil and coolant discharge and obstructions
( Page 208).
TIM-ID: 0000018474 - 003
MS150036/02E 2013-11 | Operation | 87

4.6 Tasks after extended out-of-service periods (>3 weeks)
Tasks after extended out-of-service periods (>3 weeks)

Note: Operate fuel treatment system for at least 5 minutes.
1. Start up fuel treatment system ( Page 90).
2. Shut down fuel treatment system ( Page 94).
TIM-ID: 0000007730 - 005
88 | Operation | MS150036/02E 2013-11

4.7 Checks prior to start-up
Checks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:
a) Clean affected components.
b) Disinfect affected components with biocides ( MTU Fluids and Lubricants Specifications
A001061/..).
2. Close drain valves on housing.
3. Open all supply and discharge valves.
4. Switch on fuel treatment system ( Page 93).
5. Check direction of rotation of pump.
6. Vent bypass and fuel lines of the system.
a) Open ball valve for pressure tank.
b) Open ball valve for overflow tank.
c) Close ball valve at the inlet to the fuel treatment system.
Result: Bypass line is vented via the overflow tank.
d) Open ball valve at the inlet to the fuel treatment system.
7. Check the fuel treatment system for leaks.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007736 - 005
MS150036/02E 2013-11 | Operation | 89

4.8 Fuel treatment system Putting into operation
Overview of fuel treatment system
1 Pressure-free overflow 9 Ball valve, outlet 17 Automatic water drain

2 Bypass 1 10 Check valve 700 mbar 18 Water level electrode
3 Bypass 2 11 Check valve 5 mbar 19 Ball valve, sample extrac-
4 Safety valve, 3 bar 12 Return to overflow con- tion, inlet
5 Ball valve, inlet tainer 20 Switchgear cabinet
6 Pressure gage 13 Engine 21 Pump
7 Ventilation, sample extrac- 14 Overflow container 22 Coarse filter
tion 15 Water separator filter 23 Fuel supply from tank
8 Differential pressure gage 16 Ball valve, drain 24 Tank
Switching on fuel treatment system

2. Check differential pressure at differential pressure gage (8). Differential pressure in a new system:
0.1 bar to 0.3 bar.
Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.
TIM-ID: 0000015773 - 006
1. Remove coalescer filter element ( Page 213).

2. Check sealing surfaces on coalescer filter element and in the pressure tank.
90 | Operation | MS150036/02E 2013-11

Initial operation: HAT
1. Replace fuel filter on engine ( Page 154).
Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.
2. Install pressure gage in fuel supply line from Yard fuel system to engine.
3. Switch on fuel treatment system and operate it for some minutes ( Page 93).
Result: The fuel is drawn from tank (24), cleaned by the water separator filter (15) and then routed via overflow
tank (14) back to tank (24). Water that collects in the tank is separated.
4. Start engine ( Page 86).
5. Run engine at idling speed.
6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.
Note: If the suction pressure is within the permissible limits and engine operation is satisfactory.
7. Increase engine speed to 1000 rpm and monitor suction pressure.
8. Check suction pressure at the engine-mounted fuel delivery pump.
Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter re-
placement simulation with the engine running as part of the Harbor Acceptance Tests.
Simulation of filter replacement with the engine running: HAT

4. Close ball valve (5) at inlet to fuel treatment system.
Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unit
opens and fuel flows through bypass (3) and bypass (2).
5. Open ball valve (19) .
Result: Fuel emerges. If no fuel emerges:
Open ball valve (5) at inlet to fuel treatment system.
No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .
6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.
Result: If all engine operating values are within the specified limits, open ball valve (5) at inlet to fuel treatment
system.
Simulation of power failure (emergency): HAT

4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006
MS150036/02E 2013-11 | Operation | 91

Simulation of power failure (emergency): SAT
4. Switch off pump (21) at switchgear cabinet (20).
Result: The engine-mounted fuel delivery pump draws fuel via bypass (2) directly from tank (24).
6. Operate engine at full load and monitor suction pressure.
Result: If the suction pressure is within the specified limits, simulation was successful.
TIM-ID: 0000015773 - 006
92 | Operation | MS150036/02E 2013-11

4.9 Fuel treatment system Switching on
Preconditions
The on-board power supply is switched on.
NOTICE
Risk of damage to engine/system.
Risk of severe damage to property!
Before switching on, ensure that the engine/system is ready for operation.
Before switching on, ensure that all housings are closed.
Before switching on, ensure that no work is in progress anywhere on the entire system.
Fuel treatment system Switching on

1. Carry out checks prior to start-up ( Page 89).
2. Switch on master switch on switchgear cabinet.
Result: Signal lamp Control voltage present lights up.
3. Switch on switch for pump.
Result: Signal lamp Pump running lights up.
TIM-ID: 0000007731 - 006
MS150036/02E 2013-11 | Operation | 93

4.10 Fuel treatment system Shutdown
Shutting down fuel treatment system

1. Press the illuminated pushbutton "Water drain" on the switch cabinet until water discharge from the
outlet stops.
2. Switch off fuel treatment system.
3. Close ball valve at the inlet to the fuel treatment system.
4. Close ball valve at the outlet of the fuel treatment system.
5. Open drain valve until pressure has escaped from fuel treatment system.
TIM-ID: 0000007732 - 005
94 | Operation | MS150036/02E 2013-11

4.11 Stopping the engine
Stopping the engine via the automation system
TIM-ID: 0000017528 - 004
MS150036/02E 2013-11 | Operation | 95

4.12 Emergency engine stop
NOTICE
An emergency stop causes extreme stress to the engine plant.
Risk of overheating, damage to components!
Initiate emergency stop only in emergency situations.
Emergency stop
1. Refer to automation system operating instructions.
2. Follow instructions.
TIM-ID: 0000017530 - 005
96 | Operation | MS150036/02E 2013-11

4.13 After stopping the engine
Preconditions
MTU Preservation and Re-preservation Specifications (A001070/..) are available.
After stopping the engine

Item Measure
Coolant circuit Drain coolant ( Page 194) if:
freezing temperatures are expected and the engine is to remain out of
service for an extended period, but engine coolant has no antifreeze
additive;
the engine room is not heated;
the coolant is not kept at a suitable temperature;
the antifreeze concentration is insufficient for the engine-room tem-
perature;
antifreeze concentration is 50% and engine-room temperature is below
-40 C.
Raw water (only on engines Drain
with engine-mounted heat if freezing temperatures are expected and the engine is to remain out
exchanger) of service for an extended period.
Engine control system Switch off.
Air intake and exhaust sys- Out-of-service-period > 1 week
tem
Seal engine on air and exhaust sides.
Out-of-service-period > 1 month
Preserve engine ( MTU Preservation and Re-preservation specifica-
tions A001070/..).
TIM-ID: 0000010168 - 004
MS150036/02E 2013-11 | Operation | 97

4.14 Plant Cleaning
Preconditions
Operating voltage is not applied.
Special tools, Material, Spare parts

Designation / Use Part No. Qty.
Steam jet cleaner - 1
Cleaner (Hakupur 312) 30390 1
WARNING
Compressed air gun ejects a jet of pressurized air.
Risk of injury to eyes and damage to hearing, risk of rupturing internal organs!
Never direct air jet at people.
Always wear safety goggles/face mask and ear defenders.
WARNING
Steam jet cleaner ejects jet of pressurized water.
Risk of injury to eyes and scalding!
Never direct water jet at people.
Wear protective clothing, protective gloves and safety goggles/face mask.
NOTICE
Cleaning agents should not be left to take effect for too long.
Damage to components is possible!
Observe manufacturer's instructions.
NOTICE
Blowing down product with compressed air.
Entry of dirt and damage to components is possible!
Do not aim compressed air gun directly at seals or electronic components such as connectors
or ECUs.
Plant Cleaning
1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental
protection).
2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet
unit carefully and observe the safety precautions.
3. For external cleaning of the plant with water or steam-jet cleaners:
The pressure of the high-pressure jet (cleaning jet) must not exceed 50 bar.
A minimum distance between spray nozzle and plant of 1 m must be observed.
TIM-ID: 0000010171 - 028
The temperature of the cleaning medium must not exceed 80C.

4. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.
Note: Never aim compressed air directly at electronic components.
5. Carry out external cleaning as follows:
a) Seal all openings in a suitable way.
b) Remove coarse dirt.
c) Spray on cleaner sparingly and leave it for 1 to 5 minutes.
d) Use the high-pressure jet to remove the loosened dirt.
e) Dry engine with compressed air.
98 | Operation | MS150036/02E 2013-11

5 Maintenance
5.1 Maintenance task reference table [QL1]
The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. The
Maintenance Schedule is a stand-alone publication.
The task numbers in this table provide reference to the maintenance tasks specified in the Maintenance
Schedule.
Task Option Maintenance tasks
W0500 Check engine oil level. ( Page 176)
W0501 Visually inspect engine for leaks and general condition. ( Page 87)
W0502 X Check intercooler drain(s). ( Page 171)
W0503 Check service indicator of air filter. ( Page 174)
W0504 Check relief bores of HP fuel pump . ( Page 87)
W0505 Check relief bores of water pump(s) ( Page 199)
W0506 Check engine for abnormal running noises, exhaust color ( Page 87)
and vibrations.
W0507 X Drain water and contaminants from fuel prefilter. ( Page 87)
W0508 X Check reading on differential pressure gage of fuel prefil- ( Page 87)
ter.
W1001 Replace fuel filter or fuel filter element ( Page 154)
W1005 Replace air filter. ( Page 172)
W1006 Replace injection valves/injectors. ( Page 146)
W1008 Replace engine oil filter when changing engine oil, or when ( Page 183)
the interval (years) is reached, at the latest.
W1009 X Check layer thickness of the oil residue, clean out and re- ( Page 185)
place filter sleeve, together with every oil change, at the
latest.
W1011 Perform endoscopic examination. ( Page 135)
W1016 Check condition of coupling. ( Page 206)
W1029 Inspect for tightness and damage of air duct between air ( Page 87)
filter and exhaust turbocharger.
W1036 Replace coolant filter. ( Page 201)
W1076 Clean compressor wheel. ( Page 163)
W1207 Check valve clearance, adjust if necessary. ATTENTION! ( Page 140)
First adjustment after 1,000 operating hours
TIM-ID: 0000045503 - 001
W1244 X Check function of rod electrode. ( Page 211)

W1245 X Check alarm function of differential pressure gauge. ( Page 210)
W1246 X Check pump capacity. ( Page 212)
W1463 Check general condition of engine mounting (visual inspec- ( Page 207)
tion).
W1494 X Replace filter element of fuel prefilter and sealing ring de- ( Page 161)
pending on degree of contamination, when the limit (years)
is reached, at the latest.
MS150036/02E 2013-11 | Maintenance | 99

Task Option Maintenance tasks
W1495 X Replace intermediate fuel filter or filter element. ( Page 213)
W1713 Injector: Reset drift compensation parameters (CDC). ( Page 235)
W1714 X Check and clean oil indicator filter. ( Page 181)
Table 1: Maintenance task reference table [QL1]
TIM-ID: 0000045503 - 001
100 | Maintenance | MS150036/02E 2013-11

6 Troubleshooting
6.1 Troubleshooting
Engine does not turn when starter is actuated
Cause Corrective action
Battery low or faulty u Charge or replace (see separate documentation).
Battery: Cable connections u Check firm seating of cable connections (see separate
faulty documentation).
Engine cabling or starter faulty u Check firm seating of cable connections, contact Service.
Engine cabling defective u Check ( Page 224).
Loose plug connections on u Check plug connections ( Page 226).
engine governor
Loose plug connections on u Check plug connections ( Page 228).
Engine Interface Module (EIM)
Fuse F1 ( Page 215)in engine u Check fuse (replace if required) and re-start the system by
wiring harness defective (fuse actuating the key switch.
lamp on EIM flashes with
relevant flashing code)
Running gear blocked (engine u Contact Service.
cannot be barred manually)
Engine turns on starting but does not fire

Poor rotation by starter: Battery u Charge or replace battery (see separate documentation).
low or faulty
Engine governor defective u Contact Service.
Engine fires unevenly

Injector faulty u Replace ( Page 146).
Engine does not reach nominal speed

TIM-ID: 0000010520 - 004

Easy-change fuel filter clogged u Replace ( Page 154).
Air supply: Air filter clogged u Check signal ring position of service indicator ( Page 174).
Fuel injection: Injector faulty u Replace ( Page 146).
Engine: Overload u Contact Service.
MS150036/02E 2013-11 | Troubleshooting | 101

Engine speed not steady
Speed transmitter defective u Contact Service.
Charge-air temperature too high

Incorrect coolant concentration u Check (MTU test kit).
Intercooler dirty u Contact Service.
Engine room: Air-intake u Check fans and air supply/ventilation ducts.
temperature too high
Charge-air pressure too low

Intercooler dirty u Contact Service.
Exhaust turbocharger defective u Contact Service.
Coolant leaks at intercooler

Intercooler leaky, major coolant u Contact Service.
discharge
Black exhaust gas

Engine: Overload u Contact Service.
Blue exhaust gas

Too much oil in engine u Drain engine oil ( Page 177).
Oil separator or oil-preseparator u Replace.
of crankcase breather clogged
TIM-ID: 0000010520 - 004
Exhaust turbocharger, cylinder u Contact Service.

head, piston rings, cylinder liner
defective
102 | Troubleshooting | MS150036/02E 2013-11

White exhaust gas
Engine is not at operating u Run engine to reach operating temperature.
temperature
Intercooler leaky u Contact Service.
TIM-ID: 0000010520 - 004

6.2 Fuel treatment system Troubleshooting
Illuminated pushbutton 'water alarm' is lit.
When the maximum water level 1. Press illuminated pushbutton 'Water alarm' for
is reached, the water level acknowledgment.
electrode opens the water drain 2. In addition to the automatic water drain function, water can
valve and water is discharged. If also be drained manually. To do so, press the illuminated
the opening period of the valve pushbutton 'Water drain' to open the drain valve.
exceeds a preset limit
(4 minutes), the pump will
switch off and an alarm is
initiated.
Signal lamp 'Pump fault' is lit.

The drive motor is equipped with u Reset motor protection relay.
an overload protection. If the
maximum permissible current
consumption is exceeded, e.g. in
case of a blockage or dry-
running, the motor protection
relay triggers and the pump is
switched off.
Signal lamp 'Pre-alarm' is lit.

The differential pressure u Replace coalescer filter element ( Page 213).
exceeded 1.3 bar.
Illuminated pushbutton 'Replace filter element' is lit.

The max. permissible differential 1. Replace coalescer filter element ( Page 213).
pressure of 1.5 bar was 2. Press illuminated pushbutton 'Replace filter element' for
exceeded. If the coalescer filter acknowledgment.
element is not replaced,
pressure will increase further
and the safety valve will open.
Fuel will be led via the bypass
directly into the overflow tank.
TIM-ID: 0000007734 - 008

6.3 Engine governor ADEC (ECU 7) fault messages for Series 4000
engines, marine application
The fault code numbers are generated by the engine governor and transmitted to the display below (if
fitted).
The fault code (1) comprises 3 digits.

Fault messages may also be caused by faulty sensors/actuators. Contact Service to have sensors/
actuators tested and replaced as necessary if troubleshooting as described in the table ( Page 106)
proves unsuccessful.
For explanations of alarm configuration parameters, refer to PR 2.8008.100.
Fault code list ( Page 106).
TIM-ID: 0000016867 - 006

6.4 ADEC engine governor Fault codes
29 HI ETC Idle Speed too High
ZKP-Number: 18.004.206

Idle speed of one of the u Contact Service.
secondary turbochargers is too
high.
38 AL ETC Speed Deviation


Speeds of one of the secondary 1. Reduce power.
turbochargers deviates from 2. Contact Service.
primary turbocharger speed.
39 AL ETC2 CutIn Failure


ETC2 could not be cut in. 1. Reduce power.
2. Contact Service.
81 AL Rail Leakage

Pressure gradient in rail is too u Contact Service.
low during starting or too high
during stopping (HP system
leaky or air in the system)
102 AL Cons. Counter Defect


Consumption meter faulty. u Contact Service.
TIM-ID: 0000018389 - 003
104 AL Eng Hours Counter Defect


Hourmeter faulty. u Contact Service.

141 AL Power too high

This alarm occurs if the average u Reduce power.
value of power over the last 24
hours exceeded the maximum
value specified in
PR1.1088.001.
142 AL MCR exceeded 1 hour


This alarm occurs if the MCR u Reduce power.
was exceeded for more than 1
hour within the last 12 hours.
201 SD T-Coolant

Coolant temperature sensor 1. Check sensor and cabling (B6), replace as necessary.
faulty; Short circuit or wire 2. Error cleared after restarting the engine.
break
202 SD T-Fuel

Coolant temperature sensor 1. Check sensor and cabling (B33), replace as necessary.
break
203 SD T-Charge Air


Charge-air temperature sensor 1. Check sensor and cabling (B9), replace as necessary.
TIM-ID: 0000018389 - 003
break
204 SD Level Lube Oil


lube oil level sensor faulty; Short u Check sensor and cabling, replace as necessary.
circuit or wire break

205 SD T-Coolant Intercooler

Intercooler coolant temperature u Check sensor and cabling (B26), replace as necessary.
sensor faulty; Short circuit or
wire break
206 SD T-Exhaust A

Exhaust temperature sensor on u Check sensor and cabling (B4.21), replace as necessary.
A-side faulty; Short circuit or
wire break
207 SD T-Exhaust B

B-side faulty; Short circuit or
wire break
208 SD P-Charge Air


Charge-air pressure sensor 1. Check sensor and cabling (B10), replace as necessary.
break
211 SD P-Lube Oil


Lube oil pressure sensor faulty; 1. Check sensor and cabling (B5), replace as necessary.
Short circuit or wire break 2. Error cleared after restarting the engine.
212 SD P-Coolant
TIM-ID: 0000018389 - 003

Coolant pressure sensor faulty; 1. Check sensor and cabling (B16), replace as necessary.

213 SD P-Coolant Intercooler

Intercooler coolant pressure 1. Check sensor and cabling (B43), replace as necessary.
sensor faulty; Short circuit or 2. Error cleared after restarting the engine.
wire break
214 SD P-CrankCase

Crankcase pressure sensor 1. Check sensor and cabling (B50), replace as necessary.
break
215 SD P-HD

Rail pressure sensor faulty; high- 1. Check sensor and cabling (B48), replace as necessary.
pressure regulator emergency 2. Error cleared after restarting the engine.
mode; Short circuit or wire
break
216 SD T-Lube Oil


Lube oil temperature sensor 1. Check sensor and cabling (B7), replace as necessary.
break
219 SD T-Intake Air


Intake air temperature sensor 1. Check sensor and cabling (B3), replace as necessary.
break
TIM-ID: 0000018389 - 003
220 SD Level Coolant Water


Coolant level sensor faulty; 1. Check sensor and cabling (F33), replace as necessary.

221 SD P-Diff-Lube Oil

Lube oil differential pressure 1. Check sensor and cabling (F25), replace as necessary.
wire break
222 SD Level Leakage Fuel


Leak-off fuel level sensor faulty; 1. Check sensor and cabling (F46), replace as necessary.
223 SD Level Coolant Intercooler


Coolant level sensor of 1. Check sensor and cabling (F57), replace as necessary.
intercooler faulty; Short circuit 2. Error cleared after restarting the engine.
or wire break
227 SD P-Lube Oil before Filter


Sensor for lube oil pressure 1. Check sensor and cabling (B5.3), replace as necessary.
before filter faulty; Short circuit 2. Error cleared after restarting the engine.
or wire break
228 SD P-Fuel before Filter


Fuel pressure sensor faulty; 1. Check sensor and cabling (B5.3), replace as necessary.
229 AL Stop Camshaft Sensor Defect

TIM-ID: 0000018389 - 003

Engine shutdown due to 1. Check connector and cabling to sensor B1, replace as
camshaft sensor fault (and a necessary.
prior crankshaft sensor fault in 2. Error cleared after restarting the engine.
the same operating cycle).

230 SD Crankshaft Speed

Crankshaft sensor faulty; Short 1. Check sensor and cabling (B13), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.
231 SD Camshaft Speed


Camshaft sensor faulty; Short 1. Check sensor and cabling (B1), replace as necessary.
circuit or wire break 2. Error cleared after restarting the engine.
232 SD Charger 1 Speed


Speed sensor of primary 1. Check sensor and cabling (B44.1), replace as necessary.
turbocharger faulty; Short circuit 2. Error cleared after restarting the engine.
or wire break
233 SD Charger 2 Speed


Speed sensor of secondary 1. Check sensor and cabling (B44.2), replace as necessary.
turbocharger faulty; Short circuit 2. Error cleared after restarting the engine.
or wire break
239 SD P-Diff Fuel


Fuel differential pressure sensor u Note further fault messages. Pressure sensor before or after
faulty; occurs only in filter is faulty.
combination with alarm "SD P-
Fuel before Filter" or "SD P-Fuel
after Filter".
TIM-ID: 0000018389 - 003
240 SD P-Fuel

Fuel pressure sensor faulty; 1. Check sensor and cabling (B34), replace as necessary.

241 SD T-Umblasen

Recirculation temperature 1. Check sensor and cabling (B49), replace as necessary.
wire break
242 SD T-Coolant (R)


Redundant coolant temperature 1. Check sensor and cabling, replace as necessary.
wire break
244 SD P-Lube Oil (R)


Redundant lube oil pressure 1. Check sensor and cabling, replace as necessary.
wire break
301 AL Timing Cylinder A1


Time-of-flight measuring fault of u If alarm occurs frequently, replace solenoid valve of injector
injector in cylinder A1: Time-of
flight measured value extremely
low or extremely high.


TIM-ID: 0000018389 - 003










TIM-ID: 0000018389 - 003






311 AL Timing Cylinder B1


injector B1: Time-of flight
measured value extremely low
or extremely high.


TIM-ID: 0000018389 - 003
or extremely high.


or extremely high.


or extremely high.


or extremely high.


or extremely high.


TIM-ID: 0000018389 - 003
or extremely high.


or extremely high.


or extremely high.


or extremely high.
321 AL Wiring Cylinder A1


Short-circuit in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to
to cylinder A1. Result: Misfiring negative) (e.g. by injector replacement)
2. Error cleared after restarting the engine.


TIM-ID: 0000018389 - 003











TIM-ID: 0000018389 - 003






331 AL Wiring Cylinder B1


Cabling fault in injector cabling 1. Rectify short circuit in injector solenoid valve circuit (positive to
to cylinder B1. Result: Misfiring negative) (e.g. by injector replacement)




TIM-ID: 0000018389 - 003












TIM-ID: 0000018389 - 003



341 AL Open Load Cylinder A1

Disruption fault in injector 1. Check continuity of injector cabling or exclude open load in
cabling to cylinder A1. Result: solenoid valve circuit (e.g. by injector replacement)
Misfiring 2. Error clearance: After each working cycle.








TIM-ID: 0000018389 - 003










351 AL Open Load Cylinder B1


cabling to cylinder B1. Result: solenoid valve circuit (e.g. by injector replacement)
TIM-ID: 0000018389 - 003












TIM-ID: 0000018389 - 003






361 AL Power Stage Low


Internal electronic fault u Start ITS. If the ITS diagnosis result is "electronics OK", note
(electronics possibly faulty). If further fault messages (e.g. cabling faults).
bit "1.1020.021" (Power Stage
Failure: Stop Engine) is set,
engine will be shut down as
additional measure.
362 AL Power Stage High


additional measure.
363 AL Stop Power Stage

TIM-ID: 0000018389 - 003

additional measure.

365 AL Stop MV-Wiring Ground

Injector cabling fault. If bit u Check wiring, replace wiring harness as necessary.
"1.1020.021" (Power Stage
additional measure. Possible
causes:
1. Short circuit of positive
connection of one or more
injectors to ground
2. Short circuit of negative
connection of one or more
injectors to ground
371 AL Wiring TO 1

Short circuit or wire break on 1. Check charger valve/cabling, repair as necessary.
transistor output 1 (TO 1). 2. Replace engine governor
372 AL Wiring TO 2

Short circuit or wire break on 1. Check air recirculation valve/cabling, repair as necessary
transistor output 2 (TO 2). 2. Replace engine governor
373 AL Wiring TO 3

Short circuit or wire break on u Check wiring of charger valve 2 (marine engine)
transistor output 3 (TO 3).
374 AL Wiring TO 4
TIM-ID: 0000018389 - 003

Short circuit or wire break on u Check wiring of charger valve 3 (marine engine)
transistor output 4 (TO 4).

390 AL MCR exceeded

DBR/MCR feature: MCR 1. If the alarm occurs temporarily, no action required.
(maximum continuous rating) 2. If the alarm is permanently active, contact Service.
was exceeded.
396 TD T-Coolant Sensor Deviation


Maximum deviation of coolant 1. Check sensor and cabling, replace as necessary.
temperature values from 2. Contact Service.
sensors
397 TD P-Oil Sensor Deviation


Maximum deviation of lube oil 1. Check sensor and cabling, replace as necessary.
pressure values from sensors 2. Contact Service.
417 SD Level Water Fuel Prefilter


Water level sensor in fuel u Check sensor and cabling, replace as necessary.
prefilter faulty; Short circuit or
wire break
419 SD T-Coolant b.Engine


Coolant inlet temperature u Check sensor and cabling (B3), replace as necessary.
wire break
444 SD U-PDU
TIM-ID: 0000018389 - 003

Injector power stage sensor u Replace ECU 7.
defect; Internal fault in ECU 7.

445 SD P-Ambient Air

Ambient air pressure sensor 1. Check pressure sensor and cabling, replace as necessary.
faulty. 2. Replace engine governor.
464 SD P-AUX 1

Analog input signal for Aux 1 u Check pressure sensor and cabling, replace as necessary.
pressure faulty; Short circuit or
wire break
468 SD T-AUX 1

Analog input signal for Aux 1 1. Check signal transmitter and cabling, replace as necessary.
temperature faulty; 2. Replace engine governor.
469 SD AUX 1

Analog input signal for Aux 1 u Check signal transmitter and cabling, replace as necessary.
faulty; Short circuit or wire
break
470 SD T-ECU

Temperature sensor for ECU u Check sensor and cabling, replace as necessary.
break
471 SD Coil Current

TIM-ID: 0000018389 - 003

Control of HP fuel control block u Check sensor and cabling, replace as necessary.
break

473 AL Wiring PWM_CM2

Cable break or short circuit on 1. Check cabling.
channel PWM_CM2. 2. Contact Service.
475 AL CR Trigger Engine Stop


Activated if the crash recorder 1. Determine cause of trigger/engine stop and rectify.
was triggered due to an engine 2. Contact Service.
stop.
476 AL Crash Rec. Init. Error


Crash recorder initialization 1. Check setting with DiaSys.
error. 2. Contact Service.
482 SD T-Exhaust C

wire break
483 SD T-Exhaust D

wire break

TIM-ID: 0000018389 - 003

ETC4 could not be cut in. u Check control valve on ETC 4.


ETC3 could not be cut in. u Check control valve on ETC 3.
500 AL Wiring POM Starter 1


A wiring fault was detected in u Check connection between POM and starter.
the connection between starter
1 and POM. This may be a
missing consumer, a wire break,
or a short circuit.
501 AL Wiring POM Starter 2


A wiring fault was detected in u Check connection between POM and starter.
the connection between starter
2 and POM. This may be a
missing consumer, a wire break,
or a short circuit.
502 AL Open Load POM Alternator


Open load was detected at the u Check connection between POM and starter.
connection of the battery-
charging generator on the POM.
503 AL Battery Not Charging


The battery-charging generator u Check battery-charging generator and cabling.
does not charge the battery.
TIM-ID: 0000018389 - 003
504 AL CAN POM Node Lost


POM missing on CAN bus. u Check connection and POM. If alarm occurs in combination
with alarm 508, the resistor in the POM cabling is missing.

506 AL Low Starter Voltage

battery voltage is too low to u Check battery-charging generator and cabling.
accomplish a starting
procedure.
507 AL POM Error


A general POM error occurred. u Replace POM.
508 AL Wrong POM-ID


POM transmits an unexpected u Check POM wiring harness.
ID number. If alarm occurs in
combination with alarm 504, the
resistor in the POM cabling is
missing.
519 Oillevel Calibration Error


Error when writing the 1. Check sensor and cabling, replace as necessary.
calibration value into the Flash 2. Contact Service.
or SD memory of the level
sensor; associated PV: AL Group
6 Mot Bit 11
525 SD P-Lube Oil (R2)


Redundant lube oil pressure u Check sensor and cabling, replace as necessary.
TIM-ID: 0000018389 - 003
wire break
526 SD T-Coolant (R2)


Redundant coolant temperature u Check sensor and cabling, replace as necessary.
wire break

527 TD EngineSpd. Sensor Deviation

Maximum deviation of speed 1. Check cabling of speed sensors. Observe additional messages.
sensors 2. Contact Service.
528 SD Engine Speed 3rd Sensor


Redundant crankshaft sensor u Check sensor and cabling, replace as necessary.
break
576 AL ESCM Override


Violation of corrected MCR or u Reduce power.
DBR/MCR curve. Engine
overload!
577 SD T-Lube Oil Pan


Temperature sensor in oil pan u Check sensor and cabling, replace as necessary.
defective; Short circuit or wire
break
582 AL Emergency Stop Failed


This alarm occurs if the engine u The delay between the emergency stop signal and this alarm
fails to come to a standstill signal is set in parameter 1.1005.4.
within a specified (by
parametrization) a period of time
after the emergency stop signal
TIM-ID: 0000018389 - 003
was output.
588 SD P-Oil Refill Pump


Pressure sensor faulty; Short u Check sensor and cabling, replace as necessary.

596 AL Develop PR Set

The parameter set used is a test u The alarm remains active until a series-production parameter
parameter set. set was installed.
600 SD T-Exhaust A+B


SD T-Exhaust A and T-Exhaust B u Check sensor and cabling, replace as necessary.
601 SD ETC1+ETC2

SD ETC1 and ETC2 u Check sensor and cabling, replace as necessary.
625 SD P-Fuel before Prefilter


Analog input signal for pressure 1. Check pressure sensor and cabling, replace as necessary.
before prefilter faulty; Short 2. Error cleared after restarting the engine.
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7 Task Description
7.1 Engine
7.1.1 Engine Barring manually
Preconditions

Barring device F6555766 1
Ratchet with extension F30006212 1
DANGER
Before cranking the engine, make sure that there are no persons in the engine's danger zone.
After finishing work on the engine, make sure that all safety devices are put back in place and all
tools removed from the engine.
Barring engine manually

1. Release screws (1) and remove end cov-
er (2) from flywheel housing.
TIM-ID: 0000000917 - 010
132 | Task Description | MS150036/02E 2013-11

2. Engage barring device (2) in ring gear of fly-
wheel and mount on flywheel housing.
3. Fit ratchet (1) onto barring device (2).
Note: No resistance other than compression re-
sistance must be encountered.
4. Rotate crankshaft in engine direction of ro-
tation.
Result: If the resistance exceeds the normal com-
pression resistance, contact Service.
5. Barring device is removed by same proce-
dure in reverse.
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MS150036/02E 2013-11 | Task Description | 133

7.1.2 Engine Barring with starting system
Barring using the automation system
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7.2 Cylinder Liner
7.2.1 Cylinder liner Endoscopic examination
Preconditions

Rigid endoscope Y20097353 1
Preparatory steps
1. Remove cylinder head cover ( Page 143).
2. Remove injector ( Page 147).
Positioning crankshaft at BDC

1. Using barring gear, turn crankshaft until crankshaft journal of the cylinder to be inspected has reached
BDC.
2. Insert endoscope into cylinder liner through injector seat.
Cylinder liner Endoscopic examination

Findings Action
Thin carbon coating on circumference of carbon scraper ring No action required
Slight localized additive deposits at top edge
Singular smooth areas at lower edge
Carbon deposits on circumference in clearance between top piston
ring and bottom edge of carbon scraper ring
First signs of marks left by top piston ring
Bright mark on entire circumference
Consistent honing pattern without objections
First signs of marks left by lower cooling bores
Running pattern seems darker
Dark areas with even or varying degrees of discoloration Further endoscopic examina-
Beginning and end of the discoloration are not sharply defined and tion required as part of mainte-
do not cover the entire stroke area nance work
Dark areas in the upper section of the cooling bore, remaining cir-
cumference without objections
Piston rings without objections
On the entire circumference, apart from light areas of discoloration Cylinder liner must be replaced;
(that do not impair operation) clearly darker stripes that start at the Service must be contacted
top piston ring
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Heat discoloration in the direction of stroke and honing pattern

damage
Heat discoloration of piston rings
1. Compile endoscopy report using the table.

2. Use technical terms for description of the liner surface ( Page 137).
3. Depending on findings:
do not take any action or
carry out a further endoscopic examination as part of maintenance work or
contact Service; cylinder liner must be replaced.

Final steps
1. Install injector ( Page 147).
2. Install cylinder head cover ( Page 143).
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7.2.2 Instructions and comments on endoscopic and visual examination of cylinder
liners
Terms used for endoscopic examination
Use the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic ex-
amination report.
Findings Explanations/Action
Minor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing products,
particles, broken-off burrs). Removed cylinders clearly show such scoring on the
running surface under endoscope magnification. Cannot be felt with the fingernail.
Findings not critical.
Single scores Clearly visible scores caused by hard particles. They usually start in the TDC area
and cross through the hone pattern in the direction of stroke.
Scored area These areas consist of scores of different length and depth next to one another. In
most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/
exhaust) along the transverse engine axis.
Smoothened area Smoothened areas are on the running surface but almost the whole honing pattern
is still visible. Smoothened areas appear brighter and more brilliant than the sur-
rounding running surface.
Bright area Bright areas are on the running surface and show local removal of the honing pat-
tern. Grooves from honing process are not visible any more.
Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and tempera-
ture differences around the liner. It appears rather darker within the honed struc-
ture in contrast to the bright metallic running surface. The honing pattern is undis-
turbed. Discolorations extend in stroke direction and may be interrupted.
Corrosion fields / Corrosion fields / spots result from water (condensed water) with the valves in the
spots overlap (open) position. They are clearly visible due to the dark color of the honing
groove bottom.
This corrosion is not critical unless there is corrosion pitting.
Black lines Black lines are a step towards heat discoloration. They are visible as a clear discol-
oration from TDC to BDC in the running surface and the start of localized damage
to the honing pattern.
Cylinder liners with a large number of black lines around the running surface have
limited service life and should be replaced.
Burn mark This is caused by a malfunction in the liner / ring tribosystem. Usually they run
over the whole ring-travel area (TDC/BDC), starting at the first TDC-ring and be-
coming more visible from the second TDC-ring 2 onwards and less pronounced
from TDC-ring 1. The honing pattern is usually no longer visible and displays a
clearly defined (straight) edge to the undisturbed surface. The damaged surface is
TIM-ID: 0000000014 - 015
usually discolored. The circumferential length varies.

Liners with burn marks, or heat discoloration, starting in TDC-ring 1 have to be re-
placed.
Seizure marks, scuff- Irregular circumference lengths and depths. Can be caused either by the piston
ing skirt or the piston crown. Material deposits on the liner (smear), heavy discolora-
tion. Severe, visible scoring.
Replace liner.

Evaluation of findings and further measures
The findings in the start phase of oxidation discoloration and heat discoloration are similar. A thorough
investigation and compliance with the above evaluation criteria allow an unambiguous evaluation. To
avoid unnecessary disassembly work, it is recommended that another inspection be carried out after
further operation of the engine.
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7.3 Valve Drive
7.3.1 Valve gear Lubrication
Preconditions

Engine oil
Valve gear Lubrication

1. Remove cylinder head covers
( Page 143).
2. Fill oil chambers of valve bridges with oil.
3. Fill oil chambers of rocker arms and adjust-
ing screws with oil.
4. Install cylinder head covers ( Page 143).
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7.3.2 Valve clearance Check and adjustment
Preconditions
Engine coolant temperature is max. 40 C.
Valves are closed.

Feeler gauge Y20010128 1
Torque wrench, 60-320 Nm F30047446 1
Socket wrench, 24 mm F30039526 1
Engine oil
Preparatory steps
2. Install barring gear ( Page 132).
3. The TDC mark (1) (if fitted) on the flywheel
must not be used for reference.
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4. Rotate crankshaft with barring tool in en-
gine direction of rotation until marking
'TDC-A1' and pointer are aligned.
Diagram for 12V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
Diagram for 16V engines (two

crankshaft positions)
1 Cylinder A1 is in firing TDC
2 Cylinder A1 is in overlap TDC
I Inlet valve
X Exhaust valve
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Checking valve clearance in two crankshaft positions
1. Check TDC position of piston in cylinder A1:
If the rocker arms are unloaded on cylinder A1, the piston is in firing TDC.
If the rocker arms are loaded on cylinder A1, the piston is in overlap TDC.
2. Check valve clearance with cold engine:
Inlet valves (long rocker arm) = 0.2 mm
Exhaust valves (short rocker arm) = 0.5 mm
3. Check all valve clearances at two crankshaft positions (firing and overlap TDC for cylinder A1) as per
diagram.
4. Use feeler gauge to determine the distance between valve bridge and rocker arm.
5. If the deviation from the reference value exceeds 0.1 mm, adjust valve clearance.
Valve clearance adjustment

1. Release locknut (1).
2. Insert feeler gauge (3) between valve
bridge and rocker arm.
3. Using Allen key, set adjusting screw (2) so
that the specified valve clearance is provid-
ed.
Note: Feeler gauge must just pass through the
gap.
4. Pull feeler gauge (3) between valve bridge
and rocker arm.
5. Tighten locknut (1) to the specified tightening torque, holding adjusting screw (2) firmly.
Name Size Type Lubricant Value/Standard
Locknut M16 x 1.5 Tightening torque (Engine oil) 90 Nm + 9 Nm
6. Replace or rectify adjusting screws and/or locknuts which do not move freely.
7. Check valve clearance.
Final steps
1. Remove barring gear ( Page 132).
3. Enable engine start.
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7.3.3 Cylinder head cover Removal and installation
Preconditions

Gasket ( Spare Parts Catalog)
Removing cylinder head cover

1. Clean very dirty cylinder head covers prior
to removal.
2. Remove screws.
3. Remove cylinder head cover with gasket
from cylinder head.
Installing cylinder head cover

1. Clean mating face.
2. Check condition of gasket, replace if necessary.
3. Place gasket and cylinder head cover on cylinder head.
4. Install cylinder head cover.
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7.4 Injection Pump / HP Pump
7.4.1 HP pump Filling with engine oil
Preconditions

Engine oil
WARNING
Fuels are combustible.
Risk of fire and explosion!
Avoid open flames, electrical sparks and ignition sources.
Do not smoke.
WARNING
Oils/oil vapors are combustible/explosive.
Avoid open flames, electric sparks and ignition sources.
Do not smoke.
NOTICE
HP fuel pump not filled with engine oil.
Damage to components, major material damage!
Ensure that th HP fuel pump is filled with engine oil before it is installed or put into operation.
Filling HP pump
1. Remove plug screw (1).
2. Use pump oiler to fill HP pump with engine
oil until engine oil emerges.
3. Install plug screw (1).
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7.4.2 HP pump Relief bore check
DANGER
WARNING
HP pump Relief bore check

1. Visually inspect relief bore (1) for fuel dis-
charge.
2. For jacketed HP lines, leakage is indicated
by the yellow combined alarm.
3. If fuel discharge is found or indicated, con-
tact Service.
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7.5 Injection Valve / Injector
7.5.1 Injector Replacement
Injector ( Spare Parts Catalog)
Replacing injector
u Remove injector and install new injector ( Page 147).
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7.5.2 Injector Removal and installation
Preconditions

Installation/removal tool F6789889 1
Milling cutter F30452739 1
Torque wrench, 0.5-5 Nm 0015384230 1
Ratchet F30027340 1
Ratchet F30027341 1
Assembly paste (Optimoly Paste White T) 40477 1
Grease (Kluthe Hakuform 30-10/Emulgier) X00029933 1
Engine oil
O-ring ( Spare Parts Catalog)
WARNING
Do not smoke.
Preparatory steps
1. Shut off fuel supply to engine.
Removing injector
1. Disconnect connectors on injector.
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2. Remove HP fuel line (4).
3. Remove return line (5).
Note: While the adapter is removed, the injector
is drained.
4. Remove adapter (3).
5. Remove screw (2) and take off hold-down
clamp (1).
6. Install installation/removal tool on cylinder

head.
7. Remove injector with installation/removal
tool.
8. Remove installation/removal tool.
9. Remove sealing ring (4) from injector or

use a self-made hook to take it out of the
cylinder head.
10. Remove O-rings (3), O-ring (2) and damper
ring (1) from injector.
11. Clean all mating and sealing surfaces.
12. Cover all connections and bores, or seal
with suitable plugs.
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Installing injector
1. Remove plug before installing the injec-
tor. (Do not remove the plug from the HP
line before installing the adapter.)
2. Coat injector with assembly paste at the
seat of the nozzle retaining nut.
3. Fit new sealing ring (included in the scope
of supply of the injector) with grease on in-
jector, observe installation position of seal-
ing ring.
4. Fit new O-rings (3) (included in the scope

of supply of the injector), O-ring (2) and
damping ring (1) onto the injector and coat
with grease.
5. Remove oil carbon from sealing face on cyl-
inder head and protective sleeve with mill-
ing cutter.
6. Insert injector into cylinder head, ensuring
that the HP line adapter is correctly
aligned.
7. Press in injector with installation/removal

tool.
8. Remove installation/removal tool.
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9. Coat bolt mating face (2) and thread with
engine oil.
10. Fit hold-down clamp (1) in the correct position and use torque wrench to tighten screw (2) to the speci-
fied initial tightening torque.
Screw M12 Preload torque (Engine oil) 5 Nm to 10 Nm
Note: Ensure special cleanness.
11. Coat thread and sealing cone of adapter (3) with engine oil.
12. Install adapter (3) and use torque wrench to tighten to the specified initial tightening torque.
Adapter Preload torque (Engine oil) 5 Nm to 10 Nm
13. Tighten screw (2) with torque wrench to the specified tightening torque.
Screw M12 Tightening torque 100 Nm + 10 Nm
14. Tighten adapter (3) with torque wrench to the specified tightening torque.
Adapter Tightening torque 100 Nm + 10 Nm
15. Install return line (7).
Note: Ensure special cleanness.
16. Coat thread and sealing cone of HP line (5) with engine oil.
Note: Two HP line versions (single- and double-walled) with different torques as described below.
17. Mount single-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
TIM-ID: 0000000925 - 010
sequence:
1 Rail (6)
2 Adapter (4)
Union nut / thrust Tightening torque 30 Nm + 5 Nm
screw

18. Mount double-walled HP line (5) and use torque wrench to tighten to the specified torque. Tightening
sequence:
1 Adapter (4)
2 Rail (6)
Union nut / thrust Tightening torque 40 Nm + 5 Nm
screw
19. Fit connectors on injector.
Note: Failure to reset drift compensation (CDC)
will void the emissions certification.
20. Reset drift compensation (CDC) with Dia-
Sys ( E531920/...). If DiaSys is not
available, contact Service.
Final steps
2. Open fuel supply to engine.
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7.6 Fuel Filter
7.6.1 Supplementary fuel filter Overview
1 Storage tank 3 Passive standard prefilter 5 Supplementary fuel filter

2 Day tank with water separator 6 Main engine filter
4 LP pump
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7.6.2 Additional fuel filter Replacement
Preconditions

Filter wrench F30379104 1
Diesel fuel
Easy-change filter ( Spare Parts Catalog)
Synthetic ring ( Spare Parts Catalog)
DANGER
WARNING
Do not smoke.
WARNING
NOTICE
Damage to component!
Severe material damage!
For filter replacement with the engine running, operate the engine at low engine load.
The filter which is to be replaced must be cut out for a brief period only.
Additional fuel filter Replacement

1. Replace additional fuel filter with the engine stopped ( Page 154).
2. Replace additional fuel filter with the engine running ( Page 154).
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7.6.3 Fuel filter Replacement
Preconditions

Diesel fuel
Easy-change filter ( Spare Parts Catalog)
Synthetic ring ( Spare Parts Catalog)
DANGER
WARNING
Do not smoke.
WARNING
NOTICE
Replacing fuel filter with the

engine stopped
A Both filters cut in
B Left filter cut out
C Right filter cut out
1 Fuel vent
2 Fuel filter
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1. Cut out the filter to be replaced.
2. Unscrew cut-out easy-change filter with filter wrench.
3. Clean sealing surface on filter head.
4. Check seal on new easy-change filter and moisten with fuel.
5. Fit SOLAS shield ( Page 15).
6. Screw on easy-change filter and tighten by hand.
7. Set three-way cock to normal operating position (both filters cut in).
8. Replace other fuel filters in the same way.
9. Vent fuel system (1).
Replacing fuel filter with the en-

gine running
1. Cut out the filter to be replaced.
2. Unscrew cut-out easy-change filter with fil-
ter wrench.
3. Clean sealing surface on filter head.
4. Check seal on new easy-change filter and
moisten with fuel.
6. Screw on easy-change filter and tighten by
hand.
7. Set three-way cock to normal operating po-
sition (both filters cut in).
8. Replace other fuel filters in the same way.
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7.6.4 Fuel prefilter Differential pressure check and adjustment of gauge
DANGER
WARNING
Setting adjustable pointer of dif-

ferential pressure gauge
1. After installation of a new filter element,
align adjustable pointer (2) with pressure-
indicating pointer (3) of pressure gauge (1).
2. Verify that differential pressure is within
the limit.
Fuel prefilter Checking differential pressure

1. With the engine running at full load or rated power, read off pressure at gauge (1).
2. If differential pressure as indicated between position of adjustable pointer (2) and pressure-indicating
pointer (3) of pressure gauge is 0.3 bar, flush filter element of the cut-in filter ( Page 159).
TIM-ID: 0000004925 - 008

7.6.5 Fuel prefilter Draining
Preconditions
WARNING
Do not smoke.
Draining fuel prefilter

1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out
2. Open vent plug (1) of filter to be drained.

3. Open drain valve (2).
4. Drain water and contaminants from filter
until pure fuel emerges.
5. Close drain cock (2).
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6. Connect filling pump to filling connection
(1) on the suction side of the filter.
7. Open vent valve (2) and fill with fuel until
fuel emerges from the vent pipe (3).
8. Close vent valve (2).
9. Open rotary slide valve (4) a little (by ap-
prox. 30) and open vent valve(s) (2), until
10. Close vent valve(s) (2).
11. Turn rotary slide valve (4) back to locked
position.
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7.6.6 Fuel prefilter Flushing
Diesel fuel
DANGER
WARNING
Do not smoke.
WARNING
Flushing fuel prefilter

1. Cut out dirty filter.
1 Filter A cut out
2 Filter B cut out
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2. Open vent plug (1) of filter to be flushed.
3. Open drain valve (2) and drain fuel.
Result: Fuel flows from filtered side back to the un-
filtered side, flushing the filter deposits
downwards out of the filter.
4. Close vent plug (1) and drain valve (2).
Fuel prefilter Filling with fuel

1. Stop engine ( Page 95) and disable engine start.
position.
8. Check differential pressure ( Page 156).
Result: Replace filter element in fuel prefilter
( Page 161) if flushing did not improve dif-
ferential pressure.
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7.6.7 Fuel prefilter with water separator Filter element replacement
Preconditions
System is at atmospheric pressure.

Ratchet adapter F30027340 1
Filter element ( Spare Parts Catalog)
WARNING
Tank is pressurized.
Risk of eye injuries resulting from fluid escaping under high pressure!
Open tank slowly.
Wear goggles or safety mask.
WARNING
Do not smoke.
WARNING
Component is hot.
Risk of burning!
Wear protective gloves.
Fuel prefilter with water separa-

tor Filter element replacement
1. Cut out the filter to be replaced (A or B).
1 Filter A cut out
2 Filter B cut out
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2. Open vent valve (1) of the filter to be re-
placed.
3. Open drain valve (5) and drain fuel.
4. Loosen screws (3) and screw out filter
housing (A or B).
5. Remove filter element (4).
6. Insert new filter element in filter housing.
7. Fit O-ring.
8. Reinstall filter housing (A or B) with filter el-
ement (4).
9. Tighten screws (6 or 3) to specified torque (max. half a turn per screw) using a torque wrench.
Screw Tightening torque 40 Nm
position.
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7.7 Exhaust Turbocharger
7.7.1 Compressor wheel Cleaning
Preconditions
Engine is stopped and starting disabled

Cleaning agent 40377 1
Engine oil
Engine coolant
Sealing rings ( Spare Parts Catalog) 3
Sealing rings ( Spare Parts Catalog) 4
WARNING
Chemical substances.
Risk of irritation and chemical burns!
Always obey manufacturer's instructions for use!
CAUTION
Incorrect installation of components and lines.
Ensure that components/lines are installed so that they are never under tension or strain.
Ensure correct installation position of components.
CAUTION
Unsuitable cleaning tool.
Use appropriate cleaning tool.
Preparatory steps Horizontal air intake

1. Drain engine coolant ( Page 194).
2. Remove air filter ( Page 173).
3. Seal all openings with suitable covers.
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4. Remove charge-air pipework (1) from ex-
haust turbocharger to intercooler.
5. Remove oil lines (2).
6. Loosen clamp (1).

7. Remove intake housing (3) with actuating
cylinder (2).
8. Remove coolant lines (1) from compressor

housing (3).
9. Remove coolant ventilation line (2) from
compressor housing (3).
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10. Undo screws (1).
11. Remove compressor housing (2).
Cleaning compressor wheel

Note: Do not use wire brush, scraper or similar
tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
4. Fit new sealing rings between bearing
housing/compressor housing and plug-in
sleeves if necessary.
Final steps Horizontal air in-

take
1. Install compressor housing (2).
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2. Tighten screws (1) to specified torque using a torque wrench.
Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant ventilation line and coolant lines on compressor housing.
4. Install intake housing (3) with actuating cyl-
inder (2).
5. Align clamp (1) and tighten to specified torque using a torque wrench.
Clamp Tightening torque 15 Nm + 2 Nm
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6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm + 4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter ( Page 173).
9. Fill with engine coolant ( Page 197).

Preparatory steps Vertical air intake
2. Remove air filter ( Page 173).
3. Seal all openings with suitable covers.
4. Remove charge-air pipework (1) from ex-
haust turbocharger to intercooler.
5. Remove oil lines (2).

7. Remove intake housing (3) with actuating
cylinder (2).
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8. Remove coolant lines (1) from compressor
housing (3).
9. Remove coolant ventilation line (2) from
compressor housing (3).
10. Undo screws (1).

11. Remove compressor housing (2).
Cleaning compressor wheel

Note: Do not use wire brush, scraper or similar
tools for cleaning!
1. Clean compressor housing with a smooth
paint brush or brush.
2. Clean compressor wheel (2) and bearing
housing (1).
3. Thoroughly remove cleaner from all compo-
nents.
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4. Fit new sealing rings between bearing

housing/compressor housing and plug-in
sleeves if necessary.

Final steps Vertical air intake
1. Install compressor housing (2).
2. Tighten screws (1) to specified torque using a torque wrench.

Screw Tightening torque (Engine oil) 20 Nm + 2.5 Nm
3. Install coolant ventilation line and coolant lines on compressor housing.
4. Install intake housing (3) with actuating cyl-
inder (2).
5. Align clamp (1) and tighten to specified torque using a torque wrench.
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6. Install oil lines (2). Tighten threaded adapter at actuating cylinder to specified torque using a torque
wrench.
Threaded adapter 10 G 1/4 Tightening torque (Engine oil) 40 Nm + 4 Nm
A
7. Install charge-air pipework (1) between exhaust turbocharger and intercooler.
8. Install air filter ( Page 173).
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7.8 Charge-Air Cooling
7.8.1 Charge-air cooler Checking condensate drain for water discharge and
obstruction
DANGER
WARNING
WARNING
Charge-air cooler Checking

condensate drain for water dis-
charge and obstruction
1. With the engine running, check if air
emerges from drain bore(s) on the left and
right sides on engine driving end.
Result: If no air emerges:
Clean condensate drain bore(s).
Blow out with compressed air.
2. If a large amount of coolant is continuously
discharged, the charge-air cooler is leaking.
Contact Service.
Emergency measures prior to engine start with a leaking charge-air cooler

1. Remove injectors ( Page 147).
2. Bar engine manually ( Page 132).
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3. Bar engine with starting system to blow out combustion chambers ( Page 132).
4. Install injectors ( Page 147).

7.9 Air Filter
7.9.1 Air filter Replacement
Air filter ( Spare Parts Catalog)
Replacing the air filter

1. Remove old air filter and install new air filter ( Page 173).
2. Reset signal ring of contamination indicator ( Page 174).
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7.9.2 Air filter Removal and installation
Preconditions
Air filter
2. Remove air filter (1) and clamp (2) from
connecting flange of housing (3).
3. Verify that there are no objects in the
flange of the intake housing (3) and clean
it.
4. Attach air filter (1) with clamp (2) onto in-
take housing (3).
5. Tighten clamp (2).
Air filter with intake silencer

2. Remove air filter (1) and clamp (2) from in-
take silencer (3).
3. Clean intake silencer (3) and check for ob-
structions.
4. Attach air filter (1) with clamp (2) onto in-
take silencer (1).
5. Tighten clamp (2).
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7.10 Air Intake
7.10.1 Service indicator Signal ring position check (optional)
Preconditions
Checking signal ring position

1. If the signal ring is completely visible in the
control window (2), replace air filter
( Page 172).
2. After installation of new filter, press reset
button (1).
Result: Engaged piston with signal ring moves
back to initial position.
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7.11 Starting Equipment
7.11.1 Starter Condition check
Preconditions
Checking starter condition

1. Check securing screws of starter for secure seating and tighten if required.
2. Check wiring ( Page 224).
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7.12 Lube Oil System, Lube Oil Circuit
7.12.1 Engine oil Level check
Preconditions
Oil level check prior to engine

start
1. Withdraw dipstick from guide tube and
wipe it.
2. Insert dipstick into guide tube to stop,
withdraw after approx. 10 seconds and
check oil level.
Note: After extended standstill, the oil level may
exceed the mark (1) by up to 2 cm. This
can be caused by oil flowing from e.g. oil
filter or heat exchanger back to the oil pan.
3. The oil level must reach mark (1) or exceed
mark (1) by up to 2 cm.
4. Top up with oil to mark (1) as necessary
( Page 177).
5. Insert dipstick into guide tube up to the
stop.
Oil level check after the engine is stopped

1. 5 minutes after stopping the engine, remove oil dipstick from the guide tube and wipe it.
2. Insert dipstick into guide tube to stop, withdraw after approx. 10 seconds and check oil level.
3. Oil level must be between marks (1) and (2).
4. Top up with oil to mark (1) as necessary ( Page 177).
5. Insert dipstick into guide tube up to the stop.
TIM-ID: 0000000931 - 011

7.12.2 Engine oil Change
Preconditions
Engine is at operating temperature.
MTU Fluids and Lubricants Specifications (A001061/..) are available.

Engine oil
Sealing ring ( Spare Parts Catalog)
WARNING
Hot oil.
Oil can contain combustion residues which are harmful to health.
Risk of injury and poisoning!
Wear protective clothing, gloves, and goggles / safety mask.
Avoid contact with skin.
Do not inhale oil vapor.
Oil change without semirotary hand pump: Draining oil via drain plug(s) on oil
pan
1. Provide a suitable container to collect the oil.
2. Remove drain plug(s) and drain oil.
3. Install drain plug(s) with new sealing ring.
Oil change with semirotary hand pump: Oil extraction

1. Provide a suitable container to collect the oil.
2. Draw all oil from oil pan using the semirotary hand pump.
Draining residual oil at gearcase

1. Provide a suitable container to collect the
oil.
2. Remove drain plugs (1) and (2) and drain
oil:
Approx. 12 liters at (1)
Approx. 5 liters at (2)
3. Install drain plug(s) with new sealing ring.
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4. Tighten drain plugs (1) and (2) to specified torque using a torque wrench:
Screw M26x1.5 Tightening torque (Engine oil) 100 Nm+10 Nm
Filling with new oil

1. Open cap on filler neck.
2. Pour oil in at filler neck up to 'max.' mark
at oil dipstick.
3. Close cap on filler neck.
4. Check engine oil level ( Page 176).
5. Turn engine with starting system after oil
change ( Page 134).
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7.12.3 Engine oil Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
Hot oil.
WARNING
Engine oil Sample extraction

and analysis
1. With the engine running at operating tem-
perature, open screw on centrifugal oil fil-
ter carrier by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
Dispersion capability (spot test);
Water content;
Dilution by fuel.
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Engine oil Sample extraction
and analysis (engines with
switchable oil filter)
1. With the engine running at operating tem-
perature, open screw on flange of centrifu-
gal oil filter by 1 to 2 rotations.
2. Drain approx. 2 liters engine oil to flush out
the oil sludge.
3. Drain approx. 1 liter engine oil into a clean
container.
4. Close screw.
5. Using the equipment and chemicals in the
MTU test kit, analyze the engine oil for:
Dispersion capability (spot test);
Water content;
Dilution by fuel.
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7.13 Oil Filtration / Cooling
7.13.1 Checking oil indicator filter
Preconditions
Engine shut down and secured against being restarted.

Cleaner (Snow-White 11-0) 40460 1
Cleaning agent (Hakupur 312) 30390 1
Engine oil
Strainer ( Spare Parts Catalog)
Square-section ring ( Spare Parts Catalog)
WARNING
Hot oil.
WARNING
NOTICE
Inappropriate cleaning tool.
Risk of damage to component!
Use appropriate cleaning tool.
Removing strainer
1. Clean oil indicator filter before dismantling
it.
2. Remove screws (1).
3. Take off cover (2) andh O-ring (3).
4. Remove strainer (5) from housing and allow
TIM-ID: 0000036227 - 004
oil to drip into container.

Cleaning strainer
1. Shake coarse contamination out of strainer (5).
2. Clean all metallic parts with cleaner (Snow-White 11-0), then rinse with cleaner (Hakupur 312).
3. Use a soft brush to remove stubborn deposits from strainer if required. When doing so, take care not to
damage the mesh.
4. Blow out strainer (5) with compressed air from inside.
Checking strainer
Item Findings Action
Strainer Metallic residues Clean
Monitor engine operation
Check strainer daily
Notify Service
Strainer Damaged Fit new part
Square-section ring Damaged Fit new part
O-ring Damaged Fit new part
Installing strainer
1. Coat square-section ring (4) on strainer (5) with engine oil and install strainer (5).
2. Insert strainer into housing.
3. Fill housing with new engine oil.
4. Coat O-ring (3) with engine oil and fit in filter housing.
5. Fit cover (2) and secure with screws (1) and washers.
TIM-ID: 0000036227 - 004

7.13.2 Engine oil filter Replacement
Filter wrench F30379104
Engine oil
Oil filter ( Spare Parts Catalog)
DANGER
WARNING
WARNING
Hot oil.
NOTICE
Replacing engine oil filter

1. Stop engine ( Page 95) and disable en-
gine start.
2. Unscrew oil filter using filter wrench.
3. Clean sealing surface on connecting piece.
4. Check condition of new oil filter sealing
ring and moisten it with oil.
5. Screw on and tighten new oil filter by hand.
6. Replace other oil filters in the same way.
7. Turn engine with starting system after ev-
ery oil change and filter replacement
TIM-ID: 0000014238 - 005
( Page 134).
8. Check oil level ( Page 176).

Oil filter with diverter (option):
Oil filter replacement with the
engine stopped
gine start.
2. Unscrew oil filter using oil filter wrench.
8. Turn engine with starting system after ev-
ery oil change and filter replacement
( Page 134).
Oil filter with diverter (option):

Oil filter replacement with the
engine running
1. To cut out the filter to be replaced, set the
three-way cock to the corresponding posi-
tion.
Position A: Lower filters cut out
Position B: Both filters cut in (normal op-
erating position)
Position C: Upper filters cut out.
2. Unscrew oil filter using oil filter wrench.

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7.13.3 Centrifugal oil filter Cleaning and filter sleeve replacement
Preconditions

Cleaner Hakutex 60
Grease (Kluthe Hakuform 30-10/emulsifier) X00029933 1
Filter sleeve ( Spare Parts Catalog)
WARNING
Hot oil.
WARNING
TIM-ID: 0000014256 - 004

Centrifugal oil filter Cleaning
and filter sleeve replacement
1. Remove clamp (14).
2. Release Tommy nut (2) and take off cov-
er (1).
3. Carefully lift rotor (11), allow oil to drain
and remove from housing.
4. Holding the rotor (11) firmly, release rotor
cover nut (3).
5. Take off rotor cover (4).
6. Remove filter sleeve (6).
7. Measure layer thickness of oil residues on
filter sleeve (6).
Result: If the oil residues exceed the maximum lay-
er thickness of 45 mm, shorten the mainte-
nance interval.
8. Disassemble rotor tube (7), conical disk (8)
and rotor base (10).
9. Wash rotor cover (4), rotor tube (7), conical
disk (8) and rotor base (10) with cold
cleaner.
10. Blow out with compressed air.
11. Check sealing ring (9), fit new one if neces-
sary.
12. Assemble rotor tube (7), conical disk (8)
and rotor base (10) with sealing ring (9).
13. Insert new filter sleeve (6) in rotor tube (7)
with the smooth paper surface facing the
outer wall.
14. Check sealing ring (5), fit new one if neces-
sary.
15. Mount rotor cover (4) with sealing ring (5).
16. Tighten rotor cover nut (3) with torque wrench to the specified torque.
Nut Tightening torque 35 Nm to 45 Nm
17. Place rotor (11) in housing (12) and check for ease of movement.
18. Check sealing ring (13), fit new one if necessary.
19. Fit sealing ring (13) on housing (12).
20. Fit hood (1).
21. Tighten Tommy nut (2) by hand.
22. Install clamp (14) and tighten with torque wrench to the specified torque.
Clamp Tightening torque 8 Nm to 10 Nm
TIM-ID: 0000014256 - 004
23. Tighten cover nut (2) with torque wrench to the specified torque.
Screw Tightening torque 5 Nm to 7 Nm

Cleaning centrifugal oil filter
and replacing filter sleeve (en-
gines with switchable oil filter)
1. Undo and remove screw (1).
2. Remove clamp (3) and take off hood (2).
3. Carefully remove rotor (5) from housing.
4. Hold rotor assembly (5) firmly in position
with filter wrench and undo knurled nut (7).
5. Take off rotor cap (8).
6. Remove filter sleeve (9), stiffener plate (10)
and sealing ring (11).
7. Measure thickness of oil residues on filter
sleeve.
8. If maximum layer thickness of oil residues
exceeds 30 mm, shorten maintenance in-
terval.
9. Remove standpipe (12) from lower rotor
section (13).
10. Wash hood (2), rotor cap (8), stiffener
plate (10), standpipe (12), lower rotor sec-
tion (13) and nozzles (14) with cleaner and
blow out with compressed air. Do not use
sharp objects for cleaning.
11. Check nozzles (14) for obstructions.
12. Push standpipe (12) onto rotor lower sec-
tion (13).
13. Insert new filter sleeve (9) with stiffener
plate (10) into rotor cap (8), ensuring that
the smooth surface of the filter sleeve (9)
faces the rotor cap (8).
14. Check sealing ring (11), replace if necessa-
ry. Coat sealing ring with grease and insert
in groove of rotor cap (8).
15. Place rotor cap (8) onto standpipe (12).
16. Hold rotor assembly (5) firmly in position
with filter wrench and tighten knurled
nut (7).
17. Lubricate bearings of rotor (5), insert in
housing (6) and check for ease of move-
ment.
18. Check sealing ring (4), replace if necessary.
Fit sealing ring on housing (6).
19. Fit hood (2).
20. Tighten screw (1) by hand.
21. Install clamp (3) and tighten to specified torque using a torque wrench:
TIM-ID: 0000014256 - 004

22. Tighten screw (1) to specified torque using a torque wrench:
Screw Tightening torque 6 Nm + 1 Nm

7.14 Coolant Circuit, General, High-Temperature Circuit
7.14.1 Drain and vent points
Coolant line on ETC
1 Vent point
Coolant line to intercooler

1 Vent point
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1 Vent point
Coolant line to raw water cooler

1 Vent point
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Vent line Distribution cross
1 Vent point
Coolant drain point, engine driving end

1 Drain point
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Coolant drain point, engine free end
1 Drain point
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7.14.2 Engine coolant level Check
Preconditions
WARNING
Coolant is hot and under pressure.
Risk of injury and scalding!
Let the engine cool down.
Checking engine coolant level at filler neck:

1. Turn breather valve on coolant expansion tank (for engines with remote heat exchanger: the expansion
tank is part of the remote cooling system) counterclockwise up to the first stop and allow pressure to
escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Check coolant level (coolant must be visible at the bottom edge of the cast-in eye in the filler neck).
Checking engine coolant level at

external cooler:
1. Check coolant level (coolant must be visi-
ble at marker plate).
2. Top up with treated coolant as necessary
( Page 197).
3. Check and clean breather valve.
4. Set breather valve onto filler neck and
close it.
Checking engine coolant level by means of level sensor:

1. Switch on engine control system and check readings on the display.
2. Top up with treated coolant as necessary ( Page 197).
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7.14.3 Engine coolant Change
Coolant
Engine coolant change

TIM-ID: 0000000036 - 031

7.14.4 Engine coolant Draining
Preconditions
WARNING
Preparatory steps
1. Provide an appropriate container to drain the coolant into.
2. Switch off preheating unit.
Engine coolant Draining

1. Turn breather valve on expansion tank (for engines with remote heat exchanger: the expansion tank is
part of the remote cooling system) counterclockwise up to the first stop and allow pressure to escape.
2. Continue to turn breather valve counterclockwise and remove.
3. Draw off precipitated corrosion inhibitor oil from the expansion tank through filler neck.
4. Open vent valves on carrier housing (1).
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5. Open vent valve on exhaust pipework (driv-
ing end) (1).
6. Open vent valve on seawater cooler (1) (or

remote heat exchanger).
7. Open drain plug (1) and drain coolant at

crankcase.
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8. Open drain screw (1) and drain coolant on
coolant pump elbow.
Final steps
1. Seal all open vent and drain points.
2. Set breather valve onto filler neck and close it.
TIM-ID: 0000014593 - 005

7.14.5 Engine coolant Filling
Preconditions

Engine coolant
WARNING
NOTICE
Cold coolant in hot engine can cause thermal stress.
Possible formation of cracks in the engine!
Fill / top up coolant only into cold engine.
Preparatory steps
1. Turn breather valve on expansion tank (for
engines with remote heat exchanger: the
expansion tank is part of the remote cool-
ing system) counterclockwise up to the
first stop and allow pressure to escape.
2. Continue to turn breather valve counter-
clockwise and remove.
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Filling coolant through filler
neck
1. Open vent points on charge-air cooler, ex-
haust turbochargers and on plate-core heat
exchanger (arrows).
2. Fill coolant through the filler neck of the
expansion tank (for engines with remote
heat exchanger: the expansion tank is part
of the remote cooling system) until the
coolant level at the top edge of the filler
neck remains constant.
3. When coolant emerges from the vent
points, close vent points one by one, pro-
ceeding from the lowest point upwards.
4. Check proper condition of breather valve
and clean sealing faces if required.
5. Set breather valve onto filler neck and turn
until the first stop.
7. After 10 seconds of running the engine
without load, shut down the engine
( Page 95).
8. Turn breather valve counterclockwise and
remove.
9. Check coolant level ( Page 192) and top
up engine coolant as required:
a) Repeat the steps from starting the en-
gine ( Step 6) until no coolant needs
to be topped up any more.
b) Check proper condition of breather
valve and clean sealing faces if re-
quired.
c) Set breather valve onto filler neck and
close it.
Final steps
1. Start the engine and run it without load for some minutes.
2. Check coolant level ( Page 192) and top up engine coolant as required.
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7.14.6 HT coolant pump Relief bore check
DANGER
WARNING
HT coolant pump Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
2. Stop engine ( Operating instructions elec-
tronic system) and disable engine start.
3. Clean the relief bore with a wire if it is
dirty.
Permissible engine coolant discharge:
up to 10 drops per hour;
Permissible oil discharge: up to 5 drops
per hour.
4. If discharge exceeds the specified limits,
contact Service.
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7.14.7 Engine coolant Sample extraction and analysis
Preconditions

MTU test kit 5605892099/00 1
DANGER
WARNING
WARNING
Engine coolant Sample extrac-

tion and analysis
1. Open drain valve (arrow) with the engine
running.
2. Flush sampling point by draining approx. 1
liter coolant.
3. Drain approx. 1 liter of engine coolant into
a clean container.
4. Close drain valve (arrow).
5. Use the equipment and chemicals of the
MTU test kit to check the coolant for:
Antifreeze concentration
Corrosion inhibitor concentration
pH value
6. Engine coolant change intervals ( MTU
Fluids and Lubricants Specifications).
TIM-ID: 0000014608 - 007

7.14.8 Engine coolant filter Replacement
Preconditions

Engine oil
Engine coolant filter ( Spare Parts Catalog)
WARNING
Engine coolant filter Replace-

ment
1. Remove locking device (1).
2. Close shut-off cock (3).
3. Remove engine coolant filter (2) with filter
wrench.
5. Coat seal on new engine coolant filter (2)
with engine oil.
6. Screw on engine coolant filter (2) and tight-
en hand-tight.
7. Open shut-off cock (3).
8. Install locking device (1).
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7.14.9 Preheating unit
Hotstart preheating unit
1 Plastic cap (drain) 4 Shutoff valve 7 Thermostat

2 On/Off switch 5 Continuous flow heater 8 Circulation pump
3 Plastic cap (supply line) 6 Vent valve
Cylinders Nominal voltage / frequency Heating power kW
12 V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
16 V 230 V / 50 Hz 12
400 V / 50 Hz 12
230 V / 60 Hz 12
440 V / 60 Hz 12
Function
TIM-ID: 0000014749 - 005
The preheating unit is intended to warm up the engine coolant. The circulating pump (8) ensures the
circulation of the preheated engine coolant through the engine.
The continuous flow heater (5) comprises a heating element. The thermostat (7) switches off the pre-
heating unit via contactors when the engine coolant temperature has reached the setting of the thermo-
stat (7).
In the event of excessive coolant temperature, the temperature limiter of the thermostat (7) opens the
control loop. The preheating unit is switched off.
The unit must be reset manually after the fault has been rectified.

Hilzinger preheating unit
1 On/Off switch
Cylinders Nominal voltage / frequency Heating power kW
12 V and 16 V 230 V / 50 Hz 9
400 V / 50 Hz 9
230 V / 60 Hz 9
440 V / 60 Hz 9
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Hilzinger preheating unit, side view
1 Flange (supply and return) 3 Non-return flap 5 Thermostat

2 Junction box 4 Continuous flow heater 6 Circulation pump
Function
The preheating unit is intended to warm up the engine coolant. The circulation pump (6) ensures the
circulation of the preheated coolant through the engine.
The continuous flow heater (4) comprises a heating element. A non-return flap (3) prevents coolant
from flowing through the preheating unit when the engine is running.
When the coolant temperature has reached the value of the thermostat setting (5), the thermostat (5)
switches off the preheating unit via contactors.
In the event of excessive coolant temperature, the temperature limiter of the thermostat (5) opens the
control loop. The preheater is switched off.
The unit must be reset manually after the fault has been rectified.
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7.15 Raw Water Pump with Connections
7.15.1 Raw water pump Relief bore check
DANGER
WARNING
Raw water pump Relief bore

check
1. Check relief bore for oil and coolant dis-
charge.
gine start.
3. Clean the relief bore with a wire if it is
dirty.
Permissible engine coolant discharge:
up to 10 drops per hour;
per hour.
4. If discharge exceeds the specified limits,
contact Service.
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7.16 Battery-Charging Generator
7.16.1 Battery-charging generator drive Coupling condition check
Preconditions
Battery-charging generator drive

Coupling condition check
2. Remove protective cover (2).
3. Check resilient coupling (3) for cracks and
plastic deformation.
4. If there is serious deformation or crack for-
mation, contact Service.
5. Install protective cover (2) with screws (1).
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7.17 Engine Mounting / Support
7.17.1 Engine mounting Checking securing screws for firm seating
Preconditions
Engine mounting, checking securing screws for firm seating

1. Check securing screws for firm seating.
2. Tighten loose threaded connections.
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7.18 Auxiliary PTO
7.18.1 Bilge pump Relief bore check
DANGER
WARNING
Bilge pump Relief bore check

1. Check relief bores for oil and water dis-
charge.
gine start.
3. Clean relief bores with a wire if dirty.
Permissible water discharge: up to 10
drops per hour;
per hour
4. If discharge exceeds the specified limits:
Contact Service.
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7.19 Fuel Supply System
7.19.1 Water drain valve Check
Water drain valve Check

1. Open water drain valve.
2. Check water outlet for obstructions.
3. Close water drain valve.
TIM-ID: 0000007733 - 007

7.19.2 Differential pressure gauge Check
WARNING
Do not smoke.
Checking differential pressure gauge

2. Set the alarm points at the differential pressure gauge to zero.
Result: Alarm is initiated with preset delay.
3. Reset the alarm points at the differential pressure gauge to the specified values.
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7.19.3 Water level probe (3-in-1 rod electrode) Check
Preconditions
System is put out of operation and emptied.
WARNING
Do not smoke.
Checking water level probe (3-in-1 rod electrode)

1. Disconnect connector from water level probe.
2. Unscrew water level probe.
4. Immerse water level probe into a tank filled with water until water level reaches the thread.
5. Switch system on.
Result: Water drain valve opens.
6. Leave water level probe in tank.
Result: Alarm must be triggered with the preset delay.
7. Switch off the system.
9. Remove water level probe from tank.
10. Screw in water level probe.
11. Connect connector for water level probe.
12. Fill and vent the system then put it into operation.
TIM-ID: 0000007739 - 007

7.19.4 Pump capacity Check
WARNING
Do not smoke.
Pump capacity Check

1. Install suitable pressure gauge at the neck of the intake side of the pump.
2. Check pump pressure.
a) Switch on fuel treatment system ( Page 93).
Note: The pressure limiting valve at the pump might respond and open. Audible noise is caused by overflow-
ing fuel and can be disregarded.
b) Close ball valve at the outlet of the fuel treatment system.
c) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
3. Check pump pressure with reduced suction.
a) Reduce suction pressure of pump to -0.8 bar with the shutoff valve at the pump intake side.
b) Check pressure at the pressure gauge in the inlet to the fuel treatment system and note down.
c) Open ball valve at inlet and outlet of fuel treatment system.
4. Calculate wear limit.
Example:
Measured value (normal condition). 3 bar
Measured value (reduced suction condition). 2.6 bar
If the measured value (reduced suction condition) is 10% lower than the measured value (normal condition),
the wear limit is reached. Repair pump (contact Service).
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7.19.5 Coalescer filter element Replacement
Preconditions
System is stopped and starting disabled.

Ratchet F30027339 1
Diesel fuel
Engine oil
Coalescer filter element ( Spare Parts Catalog)
Gasket ( Spare Parts Catalog)
WARNING
Do not smoke.
NOTICE
Contamination of components.
Check components for special cleanliness.
NOTICE
Incorrect installation of components and lines.
Ensure that components/lines are installed so that they are never under tension or strain.
Ensure correct installation position of components.
Coalescer filter element Re-

placement
1. Close ball valve at the inlet and outlet of
the fuel treatment system.
2. Open drain valve.
3. Drain fuel.
4. Close drain valve.
5. Remove nuts (9) and washers (2).
7. Remove cover with gasket (10).
8. Remove nut (3), washer (8) and end
TIM-ID: 0000007735 - 009
plate (4).
9. Remove coalescer filter element (5).
10. Catch fuel as it runs out.
11. Clean housing with a non-linting cloth,
rinse with fuel if required.
12. Check housing for corrosion.
13. Clean housing sealing surfaces.
14. Install coalescer filter element (5).
15. Install end plate (4), washer (8) and nut (3).

16. Tighten nut (3) to specified tightening torque using a torque wrench.
Nut M16 Tightening torque (Engine oil) 30 Nm +3 Nm
17. Fit gasket (10).
18. Install cover.
19. Install screws (1), washers (2) and nuts (9).
20. Tighten nuts (9).
21. Open ball valve at the inlet and outlet of the fuel treatment system.
Result: The fuel treatment system is ready for operation.
TIM-ID: 0000007735 - 009

7.20 Wiring (General) for Engine/Gearbox/Unit
7.20.1 Engine wiring harness Overview
Engine wiring harnesses Terminal assignment
Description Terminal assignment
Sensors B1 Camshaft speed
B3 Intake air temperature
B4.21 Exhaust temperature, A side
B4.22 Exhaust temperature, B-side
B4A1 to B4AX Cyliner exhaust temperature, engine A side
B4B1 to B4BX Cyliner exhaust temperature, engine B side
B5.1 Oil pressure downstream of filter
B5.2 Lube oil pressure
B5.3 Oil pressure upstream of filter
B6 Coolant temperature
B6.2 Coolant temperature
B7 Oil temperature
B9 Charge-air temperature
B10 Charge-air pressure
B13 Crankshaft speed
B13.2 Crankshaft speed
B16 Coolant pressure
B21 Raw water pump pressure
B33 Fuel temperature
B34.1 Fuel pressure downstream of filter
B34.2 Fuel pressure upstream of filter
B34.3 Fuel pressure upstream of external filter
B44.1 Rotation speed, turbocharger A
B44.2 Rotation speed, turbocharger B
B48 HP fuel pressure
B49 Charge air before recirculation
B50 Crankcase pressure
B54 Replenishment pump pressure
TIM-ID: 0000045753 - 001
Level monitor F33 Coolant level

XF33 Coolant level adaptation
XXF33 Coolant level, outer skin cooling
F46 Fuel overflow level
Pump M8 Fuel pump
Limit switch S37.1 Start lockout A
S37.2 Start lockout B

Description Terminal assignment
Adaptation X1 ECU-7 module
X2 ECU-7 module
X3 ECU power
X4 ECU-7 module
X11 ECU power
X12 EMU
X37 Start interlock
X52 EIM
XB19 Starting-air pressure
XD1 Dialog
XY1 Starting system
XG03 Alternator
Valves Y26 Charge-air recirculation
Y27 Turbocharger
Injectors Y39A1 to Y39AX Engine A side
Y39B1 to Y39BX Engine B side
TIM-ID: 0000045753 - 001

Engine wiring harness for sensors, 12V engine
1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 X37 17 B34.2 29 B7
6 XXF33 18 B34.1 30 B5.1
7 F33 19 B50 31 B48
8 B16 20 B49 32 B33
9 XF33 21 B44.1 33 F46
10 B54 22 Y26 34 XG03
11 B44.2 23 B5.3
12 Y27 24 B3
TIM-ID: 0000045753 - 001

Engine wiring harness for sensors, 16V engine
1 M8 13 B4.22 25 B4.21
2 B1 14 B9 26 B10
3 B6 15 S37.1 27 B13
4 X2 16 B34.3 28 S37.2
5 Y27 17 B34.2 29 B7
6 B44.2 18 B34.1 30 B5.1
7 X37 19 B50 31 B48
8 XF33 20 B49 32 B33
9 B54 21 B44.1 33 F46
10 B16 22 Y26 34 XG03
11 XXF33 23 B5.3
12 F33 24 B3
TIM-ID: 0000045753 - 001

Engine wiring harness for injectors, 12V engine
1 Y39A1 6 Y39A6 11 Y39B3

2 Y39A2 7 X4 12 Y39B2
3 Y39A3 8 Y39B6 13 Y39B1
4 Y39A4 9 Y39B5
5 Y39A5 10 Y39B4
TIM-ID: 0000045753 - 001

Engine wiring harness for injectors, 16V engine
1 Y39A1 7 Y39A7 13 Y39B5

2 Y39A2 8 Y39A8 14 Y39B4
3 Y39A3 9 X4 15 Y39B3
4 Y39A4 10 Y39B8 16 Y39B2
5 Y39A5 11 Y39B7 17 Y39B1
6 Y39A6 12 Y39B6
TIM-ID: 0000045753 - 001

Wiring harness for engine-mounted sensors, 12V engine
1 B13.2 7 X12 13 B4B3

2 B4A1 8 B6.2 14 B4B2
3 B4A2 9 B21 15 B4B1
4 B4A3 10 B4B6 16 B5.2
5 B4A4 11 B4B5
6 B4A5 12 B4B4
TIM-ID: 0000045753 - 001

Wiring harness for engine-mounted sensors, 16V engine
1 B13.2 8 B4A7 15 B4B6

2 B4A1 9 B4A8 16 B4B5
3 B4A2 10 X12 17 B4B4
4 B4A3 11 B6.2 18 B4B3
5 B4A4 12 B21 19 B4B2
6 B4A5 13 B4B8 20 B4B1
7 B4A6 14 B4B7 21 B5.2
TIM-ID: 0000045753 - 001

Wiring harness for engine interface
1 XD1 4 X52 7 XB19

2 X1 5 XY1 8 X37
3 X3 6 X11
TIM-ID: 0000045753 - 001

7.20.2 Engine wiring Check
Preconditions

Isopropyl alcohol X00058037 1
Checking engine wiring

1. Check securing screws of cable clamps on engine and tighten loose threaded connections.
2. Ensure that cables are fixed in their clamps and cannot swing freely.
3. Check that cable clamps are firm, tighten loose cable clamps.
4. Replace faulty cable clamps.
5. Visually inspect the following electrical line components for damage:
Connector housing
Contacts
Sockets
Cables and terminals
Plug-in contacts
Result: Contact Service if cable conductors are damaged.
Note: Close male connectors that are not plugged in with the protective cap supplied.
6. Clean dirty connector housings, sockets and contacts using isopropyl alcohol.
7. Ensure that all sensor connectors are securely engaged.
TIM-ID: 0000000029 - 019

7.21 Accessories for (Electronic) Engine Governor / Control System
7.21.1 Limit switch for start interlock Check
Preconditions
Note: In the OFF position, the limit switch initiates a start interlock, i.e. the engine cannot be started.
Checking limit switch for start
interlock
1. Check whether switches (3) and guard
plate (1) with engine support (4) are instal-
led on both sides of flywheel housing (2).
2. Check whether both switches (3) are actu-
ated.
3. If switches (3) and/or guard plate (1) with
engine support (4) is/are not installed:
Screw on guard plate (1) with engine
support (4).
Then screw on switch (3), ensuring that
the switch (3) is actuated by the guard
plate (1).
4. If switch (3) and guard plate (1) are instal-
led, but switch (3) is in the OFF position:
Make certain that the guard plate (1) at
the side of the switch (3) is not distort-
ed.
Release guard plate (1) and screw on
such that the switch (3) is actuated.
TIM-ID: 0000016782 - 006

7.21.2 Engine Control Unit ECU 7 Checking plug connections
Preconditions
Check plug connections on ECU

7
1. Check all connectors on ECU for firm seat-
ing. Ensure that the clips (1) are engaged.
2. Check screws (2) of cable clamps on ECU
for firm seating. Ensure that cable clamps
are not faulty.
TIM-ID: 0000016847 - 006

7.21.3 Engine monitoring unit EMU Plug connection check
Preconditions
Checking EMU plug connections

1. Check both connectors on EMU (2) for firm
seating. Make sure that frames (3) are en-
gaged.
2. Check screws (1) of cable clamps on EMU
(2) for firm seating. Make sure that cable
clamps are not defective.
TIM-ID: 0000016798 - 004

7.21.4 Interface module EIM plug connections Check
Preconditions
Checking EIM plug connections

1. Check both Tyco plugs (62-pole) (2) on EIM
for firm seating. Ensure that clips (3) are
engaged.
2. Check screws (1) of cable clamps on EIM
for firm seating. Ensure that cable clamps
are not faulty.
TIM-ID: 0000017034 - 004

7.21.5 Engine Control Unit ECU 7 Removal and installation
Preconditions
NOTICE
Wrong engine governor installed.
Engine damage!
When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing Engine Control Unit

from engine
1. Note or mark assignment of cables and
connectors.
2. Remove all screws (3).
3. Undo clips (2) on connectors.
4. Remove all male connectors.
6. Take off Engine Control Unit.
Installing Engine Control Unit on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets.
2. Check resilient mount before installing.
Result: If resilient mount is porous or defective then replace it.
TIM-ID: 0000000049 - 008

7.21.6 EMU 7 Removal and installation
Preconditions
NOTICE
Wrong engine governor installed.
Engine damage!
When reassembling an engine, make sure that the governor with the data record for the given
engine is installed.
Removing ECU with EMU from

engine
connectors.
2. Remove all screws (2).
3. Undo latches (3) of the connectors.
4. Disconnect all connectors.
6. Remove ECU (5) with EMU (4).
Removing EMU
1. Unscrew screws on base of EMU (4).
2. Remove EMU (4) from ECU (5).
Installing EMU
1. Place EMU (4) on ECU (5).
2. Screw in and tighten screws on base of EMU (4).
Installing ECU with EMU on engine

1. Install in reverse order. Ensure correct assignment of connectors and sockets in so doing.
2. Check resilient mount before installing.
Result: Replace resilient mount if porous or defective.
TIM-ID: 0000016799 - 007

7.21.7 Engine Interface Module EIM Removal and installation
Preconditions
Removing EIM from the engine

connectors.
2. Unscrew all screws (1).
3. Undo clips (2) on connectors.
4. Disconnect all connectors.
5. Unscrew power and starter cable.
7. Take off EIM.
Installing EIM on the engine

1. Install in reverse order. When doing so, observe correct assignment between cables and plugs.
2. Check seal before installing.
Result: Replace seal if porous or defective.
Downloading software
1. The new EIM still does not have appropriate FSW and parameter/descriptor module (the diagnostic
lamp (DILA) indicates flashing code 4 when the power supply is connected, ( Page 232)).
2. The FSW and the parameter/descriptor module must first be downloaded from the central database
(CDB) based on the relevant engine number using the DiaSys software tool, and then loaded in the EIM.
TIM-ID: 0000017035 - 005

7.21.8 Diagnostic features of EIM
Diagnostic lamp (DILA)
A diagnostic lamp (LED, blue) is integrated in the housing of the Engine Interface Module (EIM).
It indicates the operating status of the EIM.
Functions of diagnostic lamp DILA
DILA lights Engine Interface Module (EIM) is OK
DILA dark EIM supply voltage missing or diagnostic lamp activation is faulty.
DILA flashes Hardware or software fault in the Engine Interface Module.
The diagnostic lamp (DILA) signals the following states:
1 Time in seconds 4 Application loader active 7 No firmware

2 Timing: 1/8 s 5 External RAM faulty 8 Application crashed
3 Ready for operation 6 External FLASH faulty
Fuse lamp (SILA)

A second indicator is the fuse lamp.
TIM-ID: 0000038009 - 002
This is also integrated in the housing of the Engine Interface Module. It indicates the status of the fuses.
An orange LED is provided to allow diagnosis of a tripped fuse fault directly at the unit as it is often
difficult to pinpoint a fault in the field without cabling diagrams.
This LED is activated by the controller.
Functions of fuse lamp SILA
SILA dark Norma operating state.
SILA flashes orange One or more fuses have tripped.
The fuse lamp (SILA) signals the following states:

1 Preamble 6 VSP current path failed 11 ES pushbutton current
2 ECU current path failed (S5) path failed 24V external
(S1) 7 SLD current path failed (S10)
3 MCS current path failed (S6) 12 Key switch current path
(S2) 8 DDV current path failed failed (S11)
4 EMU current path failed (S7) 13 SDAF 1+2 current path
(S3) 9 Gear monitoring current failed (S12)
5 Starter voltage: Terminal path failed (S8) 14 PIM current path failed
30, 31 not connected and 10 Emergency stop current (S13)
PR 10.0600.001 has value path failed 24V internal 15 Spare current path failed
1 or 2 (S4) (S9) (S14)
The failed current paths are signaled consecutively following the preamble (LED on for 4 seconds (1)).
There is a pause lasting 4 seconds in between.
TIM-ID: 0000038009 - 002

Sample flashing sequences
A Fuse S5 failure (1/2 sec- B Fuse S1 and fuse S4 fail-

ond steps) ure (1/2 second steps)
Note:
These bit sequences are transmitted constantly.
Information about the status of the current paths of the EIM is also provided in the CAN message "Sta-
tus internal power supply".
TIM-ID: 0000038009 - 002

7.21.9 CDC parameters Reset
Preconditions
Note: Failure to reset drift compensation (CDC parameters) will void the emissions certification.
Resetting CDC parameters with DiaSys

u ( Dialog system DiaSys E531920/..).
Resetting CDC parameters without DiaSys

u If no DiaSys is available, contact Service.
TIM-ID: 0000044684 - 001

8 Appendix A
8.1 Abbreviations
Abbrevia- Meaning Explanation
tion
ADEC Advanced Diesel Engine Control Engine governor
AL Alarm Alarm (general)
ANSI American National Standards Institute Governing body for US American standards
ETC Exhaust turbocharger
BR Baureihe (Series)
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications, MTU Publication
No. A01061/..
CAN Controller Area Network Data bus system, bus standard
CDC Calibration Drift Compensation Setting for drift correction with DiaSys in engine gov-
ernor
CPP Controllable Pitch Propeller
DILA Diagnostic lamp on EIM
DIN Deutsches Institut fr Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche In-
dustrie-Norm")
DIS Display unit Display panel
DL Default Lost Alarm: Default CAN bus failure
ECS Engine Control System Engine management system
ECU Engine Control Unit Engine governor
EDM Engine Data Module Memory module for engine data
EIM Engine Interface Module Interface to engine monitoring system
EMU Engine Monitoring Unit
SPC Spare Parts Catalog
FPP Fixed Pitch Propeller
GCU Gear Control Unit
GMU Gear Monitoring Unit
HAT Harbor Acceptance Test
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HT High Temperature
TIM-ID: 0000002050 - 005
ICFN ISO - Continuous rating - Fuel stop Power specification in accordance with DIN-ISO
power - Net 3046-7
IDM Interface Data Module Memory module for interface data
IIG Initial Injector Equalization Entering of injector code with DiaSys in engine gover-
nor
IMO International Maritime Organization
ISO International Organization for Stand- International umbrella organization for all national
ardization standardization institutes
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
236 | Appendix A | MS150036/02E 2013-11

Abbrevia- Meaning Explanation
tion
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display, Liquid Crystal
Device
LCU Local Control Unit LOP subassembly
LED Light Emitting Diode
LMU Local Monitoring Unit LOP subassembly
LO Low Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum limit
LOP Local Operating Panel Control console, control panel
LOS Local Operating Station
MCS Monitoring and Control System
MG Message
MPU Microprocessor Unit, Microprocessing Microprocessor (unit)
Unit
TDC Top Dead Center
P-xyz Pressure-xyz Pressure measuring point xyz
PAN Panel Operating panel
PCU Propeller Control Unit
PIM Peripheral Interface Module
RCS Remote Control System
RL Redundancy Lost Alarm: Redundant CAN bus failure
SAE Society of Automotive Engineers U.S. standardization organization
SAT Sea Acceptance Test
SD Sensor Defect Alarm: Sensor failure
SDAF Shut Down Air Flaps Emergency-air shutoff flap(s)
SILA Fuse lamp on EIM
SOLAS International Convention for the Safety
of Life at Sea
SS Safety System Indicated alarm is initiated by the safety system
SSK Emergency-air shutoff flap(s)
T-xyz Temperature-xyz Temperature measuring point xyz
TD Transmitter Deviation Alarm: Sensor comparison fault
BDC Bottom Dead Center
VS Voith Schneider Voith-Schneider drive
WJ Water Jet Water jet drive
TIM-ID: 0000002050 - 005
TC Tool Catalog
ZKP Zugehrigkeit-Kategorie-Parameter Numbering plan for ADEC ECU signals
MS150036/02E 2013-11 | Appendix A | 237

8.2 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service
centers ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist
you either during operation, for preventive maintenance, corrective work in case of malfunction or
changed operating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right
spare part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse
at headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
238 | Appendix A | MS150036/02E 2013-11

9 Appendix B
9.1 Special Tools
Barring device
Part No.: F6555766
Qty.: 1
Used in: 7.1.1 Engine Barring manually ( Page 132)
Feeler gauge
Part No.: Y20010128
Qty.: 1
Used in: 7.3.2 Valve clearance Check and adjustment
( Page 140)
Filter wrench
Part No.: F30379104
Qty.: 1
Used in: 7.6.2 Additional fuel filter Replacement ( Page 153)
Qty.: 1
Used in: 7.6.3 Fuel filter Replacement ( Page 154)
Qty.:
Used in: 7.13.2 Engine oil filter Replacement ( Page 183)
Qty.: 1
Used in: 7.13.3 Centrifugal oil filter Cleaning and filter sleeve
replacement ( Page 185)
Qty.: 1
DCL-ID: 0000029503 - 001
Used in: 7.14.8 Engine coolant filter Replacement

( Page 201)
MS150036/02E 2013-11 | Appendix B | 239

Installation/removal tool
Part No.: F6789889
Qty.: 1
Used in: 7.5.2 Injector Removal and installation ( Page 147)
Milling cutter
Part No.: F30452739
Qty.: 1
MTU test kit

Part No.: 5605892099/00
Qty.: 1
Used in: 7.12.3 Engine oil Sample extraction and analysis
( Page 179)
Qty.: 1
Used in: 7.14.7 Engine coolant Sample extraction and analysis
( Page 200)
Ratchet
Part No.: F30027340
Qty.: 1
DCL-ID: 0000029503 - 001
240 | Appendix B | MS150036/02E 2013-11

Ratchet
Part No.: F30027341
Qty.: 1
Ratchet
Part No.: F30027339
Qty.: 1
Used in: 7.19.5 Coalescer filter element Replacement
( Page 213)
Ratchet adapter
Part No.: F30027340
Qty.: 1
Used in: 7.6.7 Fuel prefilter with water separator Filter ele-
ment replacement ( Page 161)
Qty.: 1
Used in: 7.7.1 Compressor wheel Cleaning ( Page 163)
Ratchet adapter
Part No.: F30027341
Qty.: 1
Used in: 7.12.2 Engine oil Change ( Page 177)
DCL-ID: 0000029503 - 001
MS150036/02E 2013-11 | Appendix B | 241

Ratchet with extension
Part No.: F30006212
Qty.: 1
Used in: 7.1.1 Engine Barring manually ( Page 132)
Rigid endoscope
Part No.: Y20097353
Qty.: 1
Used in: 7.2.1 Cylinder liner Endoscopic examination
( Page 135)
Socket wrench, 24 mm
Part No.: F30039526
Qty.: 1
( Page 140)
Steam jet cleaner

Part No.: -
Qty.: 1
Used in: 4.14 Plant Cleaning ( Page 98)
DCL-ID: 0000029503 - 001
242 | Appendix B | MS150036/02E 2013-11

Torque wrench, 0.5-5 Nm
Part No.: 0015384230
Qty.: 1
Torque wrench, 10-60 Nm

Part No.: F30510423
Qty.: 1
Used in: 7.6.7 Fuel prefilter with water separator Filter ele-
ment replacement ( Page 161)

Part No.: F30452769
Qty.: 1
Used in: 7.7.1 Compressor wheel Cleaning ( Page 163)

Part No.: F30452769
Qty.: 1
DCL-ID: 0000029503 - 001
MS150036/02E 2013-11 | Appendix B | 243

Part No.: F30027337
Qty.: 1
Used in: 7.12.2 Engine oil Change ( Page 177)

Part No.: F30027336
Qty.: 1
Used in: 7.13.3 Centrifugal oil filter Cleaning and filter sleeve
replacement ( Page 185)

Part No.: F30027336
Qty.: 1
Used in: 7.19.5 Coalescer filter element Replacement
( Page 213)

Part No.: F30047446
Qty.: 1
( Page 140)
DCL-ID: 0000029503 - 001
244 | Appendix B | MS150036/02E 2013-11

Part No.: F30452768
Qty.: 1
DCL-ID: 0000029503 - 001
MS150036/02E 2013-11 | Appendix B | 245

9.2 Index
Preheating unit202 Drain and vent points188
Drift compensation
Numerics Reset 235
12V 4000 M53R engine data72
E
A ECU 7
Abbreviations236 Installation 229
Actuators Removal 229
Overview 52 EMU 7
Additional fuel filter Installation 230
Replacement 153 Removal 230
ADEC (ECU 7) Engine
Fault messages 105 Barring manually 132
After stopping the engine97 Barring with starting system 134
Air filter Emergency stop 96
Removal and installation 173 Main dimensions 80
Replacement 172 Start 86
Stopping 95
B Wiring check 224
Battery-charging generator drive Engine Control Unit ECU 7
Coupling condition check 206 Checking plug connections 226
Bilge pump Installation 229
Relief bore check 208 Removal 229
Engine coolant
C Change 193
CDC parameters Draining 194
Reset 235 Filter replacement 201
Centrifugal oil filter Sample analysis 200
Cleaning 185 Sample extraction 200
Charge-air cooler Engine coolant level
Checking condensate drain for water discharge and Check 192
obstruction 171 Engine coolant Filling197
Checks Engine data
Prior to start-up 89 16V 4000 M53R 76
Coalescer filter element Engine governor ADEC (ECU 7)
Replacement 213 Fault messages 105
Compressor wheel Engine Interface Module EIM
Cleaning 163 Removal and installation 231
Contact persons238 Engine layout38
Controls83 Engine monitoring unit EMU 7
Coolant Plug connection check 227
Change 193 Engine mounting
Cylinder Checking securing screws for firm seating 207
Designation 14 Engine oil
Cylinder head cover Sample extraction and analysis 179
DCL-ID: 0000029503 - 001
Removal and installation 143 Engine oil

Cylinder liner Change 177
Endoscopic examination 135 Engine oil filter
Instructions and comments on endoscopic and visual Replacement 183
examination 137 Engine oil level
Check 176
D Engine sides
Designations Designation 14
Engine sides and cylinders 14 Engine wiring
Differential pressure gauge Check 224
Check 210
246 | Appendix B | MS150036/02E 2013-11

Engine wiring harness MTU contact persons238
Overview 215
O
F Oil indicator filter
Fault messages Checking 181
Engine governor ADEC (ECU 7) 105 Operational checks87
Filter
Coalescer element P
Replacement 213 Plant
Engine coolant Cleaning 98
Replacement 201 Plug connections
Filter sleeve Check 228
Replacement 185 Product description15
Firing order82 Pump capacity
Fuel Check 212
Treatment system Putting the engine into operation after extended out-of-
Switching on 93 service periods (>3 months)84
Troubleshooting 104 Putting the engine into operation after scheduled out-of-
treatment system service-period85
Shutdown 94
Fuel filter R
Replacement 154 Raw water pump
Fuel prefilter Relief bore check 205
Flushing 159
S
Fuel prefilter
Draining 157 Safety notices, standards13
Fuel prefilter with water separator Safety regulations
Filter element replacement 161 Consumables 11
Fuel prefilter Differential pressure gauge Environmental protection 11
Adjustment 156 Fire prevention 11
Check 156 Fluids and lubricants 11
Fuel treatment system Important provisions 5
Putting into operation 90 Maintenance work 8
Shutdown 94 Organizational requirements 6
Switching on 93 Personnel requirements 6
Repair work 8
H Safety notices, standards 13
Hotline238 Sensors
HP pump Overview 52
Filling with engine oil 144 Sensors and actuators Overview42
Relief bore check 145 Service indicator
HT coolant pump Signal ring position check 174
Relief bore check 199 Service partners238
Spare parts service238
I Starter
Injector Condition check 175
Installation 147 Supplementary fuel filter
Overview 152
DCL-ID: 0000029503 - 001
Removal 147
Replacement 146
Interface module EIM T
Check 228 Tasks
After extended out-of-service periods 88
L Tasks after extended out-of-service periods (>3 weeks)88
Limit switch for start interlock transport7
Check 225 Troubleshooting101
Fuel treatment system 104
M
Maintenance schedule
Maintenance task reference table [QL1] 99
MS150036/02E 2013-11 | Appendix B | 247

V
Valve clearance
Adjustment 140
Check 140
Valve gear
Lubrication 139
W
Water drain valve
Check 209
Water level probe (3-in-1 rod electrode)
Check 211
DCL-ID: 0000029503 - 001
248 | Appendix B | MS150036/02E 2013-11

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Operating Instructions

3 Technical Data 7.3 Valve Drive 139

4.1 Controls 83 7.5 Injection Valve / Injector 146

7.6.7 Fuel prefilter with water separator Filter

7.9 Air Filter 172

MS150036/02E 2013-11 | Table of Contents | 3

7.15 Raw Water Pump with Connections 205

7.16 Battery-Charging Generator 206 8.1 Abbreviations 236

7.17 Engine Mounting / Support 207 9 Appendix B

4 | Table of Contents | MS150036/02E 2013-11

MS150036/02E 2013-11 | Safety | 5

Working clothes and personal protective equipment

TIM-ID: 0000040531 - 002

6 | Safety | MS150036/02E 2013-11

Only use the lifting eyes provided to lift the engine.

Setting the engine down after transport

MS150036/02E 2013-11 | Safety | 7

Safety regulations during maintenance and repair work

8 | Safety | MS150036/02E 2013-11

Safety regulations after completion of maintenance and repair work

Hydraulic installation and removal

Working with batteries

MS150036/02E 2013-11 | Safety | 9

Working with laser equipment

TIM-ID: 0000040535 - 003

10 | Safety | MS150036/02E 2013-11

Environmental protection and disposal

Consumable fluids and materials

coming into contact with ignition sources and do not smoke.

MS150036/02E 2013-11 | Safety | 11

Paints and varnishes

Acids/alkaline solutions/urea (AdBlue, DEF)

12 | Safety | MS150036/02E 2013-11

MS150036/02E 2013-11 | Safety | 13

1 Left-hand side of engine 3 Right-hand side of engine

14 | General Information | MS150036/02E 2013-11

Centrifugal lube oil filter

MS150036/02E 2013-11 | General Information | 15

Serial RS422 interface for diagnosis

Electronic engine governor (ECU)

Electronic Engine Monitoring Unit (EMU)

16 | General Information | MS150036/02E 2013-11

1 Low-load operation 2 Cleaning cycle 3 ditto

SOLAS Fire protection specifications

MS150036/02E 2013-11 | General Information | 17

TIM-ID: 0000045751 - 001

1 Fuel line to fuel filter head

18 | General Information | MS150036/02E 2013-11

1 Fuel line on HP pump

MS150036/02E 2013-11 | General Information | 19

TIM-ID: 0000045751 - 001

1 Fuel line on fuel filter head

20 | General Information | MS150036/02E 2013-11

1 Oil supply for recirculation

MS150036/02E 2013-11 | General Information | 21

TIM-ID: 0000045751 - 001

22 | General Information | MS150036/02E 2013-11

MS150036/02E 2013-11 | General Information | 23

TIM-ID: 0000045751 - 001

24 | General Information | MS150036/02E 2013-11

MS150036/02E 2013-11 | General Information | 25

1 Oil supply for actuating 2 Oil supply for T-piece of

26 | General Information | MS150036/02E 2013-11